CN116810202A - Automatic repair welding method and system for workpiece based on quality score of welding spot - Google Patents
Automatic repair welding method and system for workpiece based on quality score of welding spot Download PDFInfo
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Abstract
The application relates to an automatic repair welding method and system for workpieces based on welding spot quality grading, in particular to the field of resistance spot welding. The system comprises a welding robot for performing a welding action on each workpiece; the welding system is used for switching welding specifications and executing a welding flow; the PLC system is used for managing welding spots and executing repair welding logic; the upper management system is used for importing a workpiece drawing, generating a workpiece configuration welding spot information list, and carrying out welding spot scoring, data acquisition and data storage; the touch screen is used for enabling a manager to download the workpiece and the welding spot information list thereof into the PLC system for storage and selecting a corresponding welding workpiece. To some occasional poor welding and false welding in welding, repair welding operation can be immediately carried out, the instant repair welding function is realized, and the production efficiency can be further improved while the quality of welding spots is ensured.
Description
Technical Field
The application relates to the field of resistance spot welding, in particular to an automatic repair welding method and system for workpieces based on quality scores of welding spots.
Background
Resistance spot welding is a high-efficiency and economical welding method and is widely applied to the fields of automobiles, aerospace, household appliances and the like. At present, the welding quality is mainly detected through a destructive test, the destructive test is a sampling inspection method, and the sampling number cannot be too small in order to ensure the welding quality, so that the inspection workload is increased, the production efficiency is reduced, and an additional welding sample is needed for inspection, so that the welding cost is further improved. The destructive sampling inspection wastes a great deal of manpower and material resources, but can not completely ensure the welding quality, so that the development of a nondestructive resistance spot welding quality detection method is necessary.
The spot welding process is a multi-field coupling process, and relates to the physical and chemical changes of electric heat, force, metallurgy and the like, wherein the physical and chemical changes can generate a series of characteristic signals reflecting the spot welding quality, and the welding quality can be indirectly detected by processing and analyzing the acquired signal information.
By searching, the following patent documents related to the present application are found, the specific contents of which are as follows:
CN106483195a discloses a method and system for detecting and controlling quality of self-adaptive resistance spot welding, wherein the method comprises: constructing a basic knowledge base for adjusting welding process parameters and a welding spot quality detection knowledge base; in the process of performing resistance spot welding, scanning a welding spot through an ultrasonic probe, collecting welding process parameters corresponding to the welding spot in real time, and obtaining an ultrasonic signal of the welding spot and imaging the welding spot; performing quality detection on welding spots according to the obtained ultrasonic signals, the welding spot imaging and the constructed welding spot quality detection knowledge base to obtain quality detection results; when the quality detection result is qualified, the acquired welding process parameters corresponding to the welding spots are utilized to update a basic knowledge base, and in the subsequent resistance spot welding process, the welding process parameters are adaptively adjusted according to the updated basic knowledge base and by utilizing a fuzzy control method, so that the quality detection of the welding spots and the welding process parameter adjustment are combined, and the welding quality of the welding spots is improved.
Therefore, the application does not accurately detect the process flow, so that the welding quality is lower.
Disclosure of Invention
Aiming at the defects of the prior art, the application provides a workpiece automatic repair welding method and system based on welding spot quality grading, which track and control the welding spot quality of each workpiece so as to improve the welding quality of welding spots.
In order to achieve the above object, the present application provides the following technical solutions:
a workpiece automatic repair welding method based on welding spot quality grading comprises
Step S1, a manager imports a workpiece drawing into an upper management system;
step S2, a manager configures a welding spot information list for the successfully imported workpiece, and downloads the workpiece and the welding spot information list thereof to a PLC system for storage after confirming that the information in the welding spot information list is consistent with the actual welding process.
S3, the manager puts the workpiece into a clamp, selects Part ID of the workpiece through a touch screen and sends the Part ID to the PLC system to prepare for welding;
step S4, the PLC system controls the welding robot and the welding system to weld the first welding spot, and simultaneously collects various welding parameters to calculate a predicted characteristic value of a welding curve, and uploads the predicted characteristic value to the upper management system;
s5, the upper management system stores the predicted characteristic value of the welding curve into a database, evaluates the welding spot quality of the workpiece according to a curve evaluation algorithm, gives a welding spot score, and judges whether the welding spot mark is qualified or not according to the welding spot score;
s6, welding a next welding spot on the workpiece with qualified welding spot marks, performing repair welding operation on the workpiece with unqualified welding spot marks, and after the repair welding is finished, recording and storing a final welding result and repair welding times of the welding spot by the upper management system;
and S7, after all welding of welding spots of the workpiece are finished, if the welding state of one or a plurality of points in the welding spot information list of the workpiece is unqualified, marking the workpiece as unqualified by the upper management system, and sending out a warning.
In step S4, a predicted characteristic value of the welding curve is set to λ
λ＝f(HR 0 I w F w )
Wherein H is the thickness of the workpiece, R 0 For initial resistance of the work piece, I w For welding current, F w Is the welding pressure.
In step S5, the welding point score is set to E
Wherein n is the number of predicted characteristic values of the welding curve, i is the ith predicted characteristic value, omega i Is the weight of the ith eigenvalue.
In the step S5, moreover, the upper management system is provided with a welding score threshold P and a welding score criterion S,
if P is more than or equal to S, the upper management system judges that the welding spot marks are qualified, and the welding of the next welding spot is performed;
if P is less than S, the upper management system judges that the welding spot mark is unqualified, and repair welding operation is performed.
In the step S6, the PLC system is provided with a maximum repair welding number for each workpiece welding spot, and repair welding is permitted if the maximum repair welding number of the welding spot is greater than 1, and repair welding is not performed if the maximum repair welding number of the welding spot is less than 1.
And the manager sets the importance degree of the welding spot part of each workpiece in the PLC system, and the PLC system determines the maximum repair welding times of the workpieces according to the importance degree of the welding spot part.
And after the repair welding of the welding spot of the workpiece is finished, scoring the welding result of the welding spot again until the upper management system judges that the welding spot mark is qualified or the repair welding frequency of the welding spot reaches the maximum repair welding frequency, and ending the repair welding operation of the welding spot.
A system for automatic repair welding method of workpiece based on quality score of welding spot comprises
The welding robot is used for executing welding actions on each workpiece;
the welding system is connected with the welding robot and used for switching welding specifications and executing a welding process;
the PLC system is connected with the welding system and used for managing welding spots and executing repair welding logic;
the upper management system is connected with the PLC system and used for importing a workpiece drawing, generating a workpiece configuration welding spot information list, scoring welding spots, collecting data and storing data;
the touch screen is respectively connected with the PLC system and the upper management system and used for enabling a manager to download the workpiece and the welding spot information list thereof into the PLC system for storage and select a corresponding welding workpiece.
Compared with the prior art, the application has the beneficial effects that:
the upper management system can display the welding state and the welding spot scoring result in the welding spot information configuration list in real time, and simultaneously visually presents the welding spot scoring result to a manager in cooperation with a workpiece drawing which is pre-led, so that the visualization of welding spot quality judgment is further realized.
Compared with the traditional detection of welding quality, the application can immediately perform repair welding operation on the problems of occasional poor welding and false welding in welding, realizes the instant repair welding function, and can further improve the production efficiency while ensuring the quality of welding spots.
According to the application, the predicted characteristic value of the welding curve is calculated, and then the welding spot quality of the workpiece is evaluated according to the curve evaluation algorithm to judge whether the welding spot mark is qualified, so that each welding spot can be independently set with a welding spot scoring threshold value and the maximum repair welding times according to actual conditions, and the welding quality of the welding spot is further improved.
According to the application, the predicted characteristic values of the welding curve are calculated by collecting various welding parameters, and then the welding spot quality of the workpiece is evaluated according to a curve evaluation algorithm, so that the online real-time detection of the welding quality is further realized, the quality of a welding product is further improved, and the outflow of defective products is avoided.
The upper management system is used for importing a workpiece drawing and generating a workpiece configuration welding spot information list, and meanwhile has the functions of welding spot scoring, data acquisition and data storage so as to achieve a traceable result of the data of each welding spot of each workpiece.
Drawings
FIG. 1 is a flow chart of a method for automatic repair welding of workpieces based on weld quality scores according to the present application.
FIG. 2 is a logic block diagram of a system for an automatic repair welding method for workpieces based on weld quality scores in accordance with the present application.
FIG. 3 is a logic block diagram of an automatic repair welding method for workpieces based on weld quality scores according to the present application.
Fig. 4 is a repair welding logic diagram of the automatic repair welding method for workpieces based on the quality scores of welding spots according to the application.
Detailed Description
In order to make the objects, technical solutions and advantages of the present application more apparent, the technical solutions of the present application will be described in detail below. It will be apparent that the described embodiments are only some, but not all, embodiments of the application. All other embodiments, based on the examples herein, which are within the scope of the application as defined by the claims, will be within the scope of the application as defined by the claims.
As shown in fig. 1 to 4, the present application provides a technical solution: a workpiece automatic repair welding method based on welding spot quality grading comprises
Step S1, a manager imports a workpiece drawing into an upper management system;
step S2, a manager configures a welding spot information list for the successfully imported workpiece, and downloads the workpiece and the welding spot information list thereof to a PLC system for storage after confirming that the information in the welding spot information list is consistent with the actual welding process.
S3, the manager puts the workpiece into a clamp, selects Part ID of the workpiece through a touch screen and sends the Part ID to the PLC system to prepare for welding;
step S4, the PLC system controls the welding robot and the welding system to weld the first welding spot, and simultaneously collects various welding parameters to calculate a predicted characteristic value of a welding curve, and uploads the predicted characteristic value to the upper management system;
s5, the upper management system stores the predicted characteristic value of the welding curve into a database, evaluates the welding spot quality of the workpiece according to a curve evaluation algorithm, gives a welding spot score, and judges whether the welding spot mark is qualified or not according to the welding spot score;
s6, welding a next welding spot on the workpiece with qualified welding spot marks, performing repair welding operation on the workpiece with unqualified welding spot marks, and after the repair welding is finished, recording and storing a final welding result and repair welding times of the welding spot by the upper management system;
and S7, after all welding of welding spots of the workpiece are finished, if the welding state of one or a plurality of points in the welding spot information list of the workpiece is unqualified, marking the workpiece as unqualified by the upper management system, and sending out a warning.
In the embodiment of the application, the workpiece drawing requirements are STEP or STL format, and each workpiece drawing has unique Part ID.
In the embodiment of the application, the welding spot information comprises a welding spot number, a welding specification number, a welding spot scoring threshold value and a maximum repair welding frequency.
Specifically, in the step S4, the predicted characteristic value of the welding curve is λ, and the welding curve is set
λ＝f(HR 0 I w F w )
Wherein H is the thickness of the workpiece, R 0 For initial resistance of the work piece, I w For welding current, F w Is the welding pressure.
Specifically, in the step S5, the welding point score is E, and the welding point score is set
Wherein n is the number of predicted characteristic values of the welding curve, i is the ith predicted characteristic value, omega i Is the weight of the ith eigenvalue.
Specifically, in the step S5, the upper management system is provided with a welding score threshold P and a welding score standard S,
if P is more than or equal to S, the upper management system judges that the welding spot marks are qualified, and the welding of the next welding spot is performed;
if P is less than S, the upper management system judges that the welding spot mark is unqualified, and repair welding operation is performed.
In the embodiment of the application, the welding score threshold value P is 0-100.
Specifically, in the step S6, the PLC system is provided with a maximum repair welding number for each workpiece welding spot, and repair welding is allowed if the maximum repair welding number of the welding spot is greater than 1, and repair welding is not performed if the maximum repair welding number of the welding spot is less than 1.
Specifically, the manager sets the importance degree of the welding spot part of each workpiece in the PLC system, and the PLC system determines the maximum repair welding times of the workpieces according to the importance degree of the welding spot part.
Specifically, after the repair welding of the welding spot of the workpiece is completed, scoring the welding result of the welding spot again until the upper management system judges that the welding spot mark is qualified or the repair welding frequency of the welding spot reaches the maximum repair welding frequency, and ending the repair welding operation of the welding spot.
The application provides a technical scheme that: a system for automatic repair welding method of workpiece based on quality score of welding spot comprises
The welding robot is used for executing welding actions on each workpiece;
the welding system is connected with the welding robot and used for switching welding specifications and executing a welding process;
the PLC system is connected with the welding system and used for managing welding spots and executing repair welding logic;
the upper management system is connected with the PLC system and used for importing a workpiece drawing, generating a workpiece configuration welding spot information list, scoring welding spots, collecting data and storing data;
the touch screen is respectively connected with the PLC system and the upper management system and used for enabling a manager to download the workpiece and the welding spot information list thereof into the PLC system for storage and select a corresponding welding workpiece.
The above embodiments are only for illustrating the technical method of the present application and not for limiting the same, and it should be understood by those skilled in the art that the technical method of the present application may be modified or substituted without departing from the spirit and scope of the technical method of the present application.
Claims (8)
1. An automatic repair welding method for workpieces according to quality scores of welding spots is characterized by comprising the following steps:
step S1, a manager imports a workpiece drawing into an upper management system;
step S2, a manager configures a welding spot information list for the successfully imported workpiece, and downloads the workpiece and the welding spot information list thereof to a PLC system for storage after confirming that the information in the welding spot information list is consistent with the actual welding process.
S3, the manager puts the workpiece into a clamp, selects Part ID of the workpiece through a touch screen and sends the Part ID to the PLC system to prepare for welding;
step S4, the PLC system controls the welding robot and the welding system to weld the first welding spot, and simultaneously collects various welding parameters to calculate a predicted characteristic value of a welding curve, and uploads the predicted characteristic value to the upper management system;
s5, the upper management system stores the predicted characteristic value of the welding curve into a database, evaluates the welding spot quality of the workpiece according to a curve evaluation algorithm, gives a welding spot score, and judges whether the welding spot mark is qualified or not according to the welding spot score;
s6, welding a next welding spot on the workpiece with qualified welding spot marks, performing repair welding operation on the workpiece with unqualified welding spot marks, and after the repair welding is finished, recording and storing a final welding result and repair welding times of the welding spot by the upper management system;
and S7, after all welding of welding spots of the workpiece are finished, if the welding state of one or a plurality of points in the welding spot information list of the workpiece is unqualified, marking the workpiece as unqualified by the upper management system, and sending out a warning.
2. The automatic repair welding method according to the welding quality score of claim 1, wherein in the step S4, the predicted characteristic value of the welding curve is λ, and the welding curve is set to be
λ＝f(HR 0 I w F w )
Wherein H is the thickness of the workpiece, R 0 For initial resistance of the work piece, I w For welding current, F w Is the welding pressure.
3. The automatic repair welding method according to the welding spot quality score according to claim 1, wherein in the step S5, the welding spot score is E, and the welding spot quality score is set as
Wherein n is the number of predicted characteristic values of the welding curve, i is the ith predicted characteristic value, omega i Is the weight of the ith eigenvalue.
4. The automatic repair welding method according to the quality score of a welding spot according to claim 3, wherein in the step S5, a welding score threshold P and a welding score standard S are set in the upper management system,
if P is more than or equal to S, the upper management system judges that the welding spot marks are qualified, and the welding of the next welding spot is performed;
if P is less than S, the upper management system judges that the welding spot mark is unqualified, and repair welding operation is performed.
5. The automatic repair welding method according to the quality score of the welding spots according to claim 1, wherein in the step S6, the PLC system is provided with a maximum repair welding number for each welding spot of the workpiece, and repair welding is allowed if the maximum repair welding number of the welding spot is greater than 1, and repair welding is not performed if the maximum repair welding number of the welding spot is less than 1.
6. The automatic repair welding method according to the quality score of welding spots for workpieces according to claim 5, wherein the manager sets the importance degree of the welding spot portion of each workpiece in the PLC system, and the PLC system determines the maximum repair welding number of the workpieces according to the importance degree of the welding spot portion.
7. The automatic repair welding method according to the quality score of the welding spot of claim 6, wherein after the repair welding of the welding spot of the workpiece is completed, the welding result of the welding spot is scored again until the upper management system judges that the welding spot mark is qualified or the repair welding frequency of the welding spot reaches the maximum repair welding frequency, and then the repair welding operation of the welding spot is ended.
8. The system of automatic repair welding of workpieces according to weld quality score of any of claims 1-7, comprising
The welding robot is used for executing welding actions on each workpiece;
the welding system is connected with the welding robot and used for switching welding specifications and executing a welding process;
the PLC system is connected with the welding system and used for managing welding spots and executing repair welding logic;
the upper management system is connected with the PLC system and used for importing a workpiece drawing, generating a workpiece configuration welding spot information list, scoring welding spots, collecting data and storing data;
the touch screen is respectively connected with the PLC system and the upper management system and used for enabling a manager to download the workpiece and the welding spot information list thereof into the PLC system for storage and select a corresponding welding workpiece.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202310794495.9A CN116810202A (en) | 2023-06-30 | 2023-06-30 | Automatic repair welding method and system for workpiece based on quality score of welding spot |
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| CN202310794495.9A CN116810202A (en) | 2023-06-30 | 2023-06-30 | Automatic repair welding method and system for workpiece based on quality score of welding spot |
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