CN117381117B - Multi-angle resistance welding equipment - Google Patents
Multi-angle resistance welding equipment Download PDFInfo
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- CN117381117B CN117381117B CN202311703568.5A CN202311703568A CN117381117B CN 117381117 B CN117381117 B CN 117381117B CN 202311703568 A CN202311703568 A CN 202311703568A CN 117381117 B CN117381117 B CN 117381117B
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- 238000003466 welding Methods 0.000 title claims abstract description 652
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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
- B23K11/00—Resistance welding; Severing by resistance heating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/30—Features relating to electrodes
- B23K11/31—Electrode holders and actuating devices therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/36—Auxiliary equipment
Abstract
The invention relates to the technical field of resistance welding, in particular to multi-angle resistance welding equipment. The invention provides multi-angle resistance welding equipment which comprises a welding pressure monitoring and analyzing module. The welding pressure monitoring and analyzing module comprises: the welding pressure monitoring and analyzing device comprises a welding pressure collector, a resistance welding gun pose adjusting mechanism and a welding pressure monitoring and analyzing controller. The welding pressure monitoring and analyzing controller is used for analyzing the welding pressure when the resistance welding gun is in contact with the resistance to obtain a welding pressure predicted value and a corresponding optimal welding angle, and outputting a control instruction through the resistance welding gun pose adjusting mechanism to control the resistance welding gun to act so as to adjust the resistance welding gun to the optimal welding angle. The invention achieves more efficient and accurate resistance welding.
Description
Technical Field
The invention relates to the technical field of resistance welding, in particular to multi-angle resistance welding equipment.
Background
With the development of technology, resistance welding equipment is becoming more and more widely used, covering almost all manufacturing and industrial fields where metal part connections are required. The method has the advantages of being capable of providing quick, firm and reliable welding connection and being suitable for large-scale production and scenes requiring high-quality connection. For workpieces with complex structures, welding may need to be performed at different angles to ensure complete coverage of all the joints. The multi-angle resistance welding device can provide flexibility and adapt to various welding requirements. For some applications, weld quality is critical, and different angles may affect the quality of the weld. The multi-angle resistance welding apparatus can ensure consistent welding quality at different angles.
At present, it is common that a resistance welding device is resistance welding with a single angle, and this resistance welding device has relatively poor adaptability because of a single welding angle, and may require a customized fixture or multiple adjustments of welding positions for workpieces with different shapes and structures, which increases the complexity of operation.
Disclosure of Invention
In order to solve the technical problem that efficiency of single-angle welding equipment is low when processing multi-angle welding requirements, the invention aims to provide multi-angle resistance welding equipment, and the adopted technical scheme is as follows:
the invention provides multi-angle resistance welding equipment, which comprises a resistance welding equipment body, wherein the resistance welding equipment body comprises a resistance welding gun, the resistance welding equipment also comprises a welding pressure monitoring and analyzing module, the welding pressure monitoring module is arranged on the resistance welding equipment body, and the welding pressure monitoring and analyzing module comprises: a welding pressure collector, a resistance welding gun pose adjusting mechanism and a welding pressure monitoring analysis controller;
the signal output end of the welding pressure collector is connected with the signal input end of the welding pressure monitoring and analyzing controller, the signal output end of the welding pressure monitoring and analyzing controller is connected with the signal input end of the resistance welding gun pose adjusting mechanism, and the resistance welding gun pose adjusting mechanism is used for being assembled and connected with a resistance welding gun and adjusting the pose state of the resistance welding gun;
the welding pressure collector is used for obtaining the welding pressure when the resistance welding gun is in contact with the resistance and outputting the welding pressure to the welding pressure monitoring analysis controller; the welding pressure monitoring and analyzing controller preprocesses the welding pressure to obtain a resistance welding pressure value; analyzing according to the resistance welding pressure values at adjacent moments in the resistance welding pressure value sequence to obtain the stability of the resistance welding pressure value sequence; adjusting the resistance welding pressure value sequence in combination with the stability to obtain a stable welding pressure value sequence; analyzing the possibility that the resistance welding pressure value is abnormal noise and the data trend condition of the resistance welding pressure value in the stable welding pressure value sequence, and determining the pressure weight of the resistance welding pressure value; based on the pressure weight, carrying out weighted averaging on the data in the stable welding pressure value sequence to obtain a welding pressure predicted value; determining an optimal welding angle according to the predicted welding pressure value; and outputting a control instruction to the resistance welding gun pose adjusting mechanism according to the optimal welding angle, wherein the control instruction is used for controlling the action of the resistance welding gun so as to adjust the resistance welding gun to the optimal welding angle.
Preferably, the analyzing according to the resistance welding pressure values at adjacent time in the resistance welding pressure value sequence to obtain stability of the resistance welding pressure value sequence includes:
analyzing according to the difference of the resistance welding pressure values at adjacent moments in the resistance welding pressure value sequence to obtain a characteristic value of each resistance welding pressure value; and determining the stability of the resistance welding pressure value sequence by combining the fluctuation condition of the characteristic value of the resistance welding pressure value.
Preferably, the analyzing according to the difference between the resistance welding pressure values at adjacent times in the resistance welding pressure value sequence to obtain the characteristic value of each resistance welding pressure value includes:
taking the resistance welding pressure value at any moment as a target pressure value; taking the ratio of the resistance welding pressure value at the moment before the target pressure value and the target pressure value as a first ratio; taking the ratio of the target pressure value and the resistance welding pressure value at the later moment as a second ratio; and taking the absolute value of the difference value of the first ratio and the second ratio as the characteristic value of the target pressure value.
Preferably, the determining stability of the sequence of resistance welding pressure values in combination with fluctuation of the characteristic value of the resistance welding pressure values includes:
the stability is calculated according to the following formula:
the method comprises the steps of carrying out a first treatment on the surface of the Wherein (1)>Stability for the sequence of resistance welding pressure values; e is a natural constant; />The number of resistance welding pressure values in the sequence of resistance welding pressure values; />For the resistance welding pressure value sequence +.>Characteristic values of the resistance welding pressure values; />Is the average of the characteristic values of all the resistance welding pressure values in the resistance welding pressure value sequence.
Preferably, the analyzing the probability that the resistance welding pressure value is abnormal noise and the data trend situation of the resistance welding pressure value in the stable welding pressure value sequence, determining the pressure weight of the resistance welding pressure value includes:
determining the abnormal possibility of each resistance welding pressure value according to the possibility that the resistance welding pressure value in the stable welding pressure value sequence is abnormal noise;
determining the data universality trend of each resistance welding pressure value according to the data trend condition of the resistance welding pressure value;
and taking the normalized value of the ratio of the data universality trend and the abnormality probability as the pressure weight of the resistance welding pressure value.
Preferably, the determining the abnormal probability of each resistance welding pressure value according to the probability that the resistance welding pressure value in the stable welding pressure value sequence is abnormal noise comprises:
the calculation formula of the anomaly possibility is as follows:
the method comprises the steps of carrying out a first treatment on the surface of the Wherein (1)>To stabilize the ith resistance weld in a sequence of weld pressure valuesThe possibility of abnormality of the pressure value; />The ith resistance welding pressure value in the sequence of stable welding pressure values; />The (i+1) resistance welding pressure value in the sequence of stable welding pressure values; />The i-1 resistance welding pressure value in the sequence of stable welding pressure values; />In order to stabilize the welding pressure value sequence, in addition to the resistance welding pressure value +.>The number of other resistance welding pressure values; />For stabilizing the resistance welding pressure value in the sequence of welding pressure values +.>Total number of occurrences; />In order to stabilize the welding pressure value sequence, in addition to the resistance welding pressure value +.>External->The number of times the data appears in the sequence of steady pressure values; />The number of resistance welding pressure values in the sequence of stabilizing pressure values; />To stabilize the sequence of pressure valuesAnd (5) an average value of the resistance welding pressure values.
Preferably, the determining the data universality trend of each resistance welding pressure value according to the data trend condition of the resistance welding pressure value includes:
the calculation formula of the data universality trend is as follows:
the method comprises the steps of carrying out a first treatment on the surface of the Wherein (1)>The data universality trend of the ith resistance welding pressure value in the stable welding pressure value sequence is that; />The number of resistance welding pressure values in the sequence of stabilizing pressure values; />The ith resistance welding pressure value in the sequence of stable welding pressure values; />The method comprises the steps of stabilizing the I-j resistance welding pressure values in a welding pressure value sequence; e is a natural constant.
Preferably, the determining the optimal welding angle according to the predicted welding pressure value includes:
when the predicted welding pressure value is larger than the preset pressure value, the ant colony algorithm is utilized to input the predicted welding pressure value and the preset pressure value, and the optimal welding angle is obtained.
Preferably, the adjusting the sequence of resistance welding pressure values in combination with the stability to obtain a sequence of stable welding pressure values includes:
and when the stability is smaller than a preset stability threshold, adding a preset number of resistance welding pressure values in the resistance welding pressure value sequence to obtain a stable welding pressure value sequence.
Preferably, the preprocessing the welding pressure to obtain a resistance welding pressure value includes:
and preprocessing the welding pressure by using a self-adaptive step difference method to obtain a resistance welding pressure value.
The embodiment of the invention has at least the following beneficial effects:
according to the invention, the welding pressure monitoring and analyzing module is deployed on the resistance welding equipment, wherein the welding pressure when the resistance welding gun is in contact with the resistance can be obtained through the welding pressure collector in the welding pressure monitoring and analyzing module, the welding pressure is analyzed and processed to obtain a predicted welding pressure value and a corresponding optimal welding angle, and a control instruction is output through the resistance welding gun pose adjusting mechanism for controlling the action of the resistance welding gun so as to adjust the resistance welding gun to the optimal welding angle. Since abnormal noise data may exist in the initially collected welding pressure, stability of the welding pressure is analyzed, and the sequence of resistance welding pressure values is adjusted in combination with the stability to eliminate the influence of the abnormal noise data. And carrying out weighted averaging on the data in the stable welding pressure value sequence to realize the prediction of the welding pressure and obtain a predicted welding pressure value. Finally, determining an optimal welding angle according to the predicted welding pressure value; and outputting a control instruction to the resistance welding gun pose adjusting mechanism according to the optimal welding angle, and controlling the resistance welding gun to act in real time so as to adjust the resistance welding gun to the optimal welding angle, thereby realizing more efficient and more accurate resistance welding.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions and advantages of the prior art, the following description will briefly explain the drawings used in the embodiments or the description of the prior art, and it is obvious that the drawings in the following description are only some embodiments of the invention, and other drawings can be obtained according to the drawings without inventive effort for a person skilled in the art.
FIG. 1 is a block diagram of a multi-angle resistance welding apparatus according to one embodiment of the present invention;
FIG. 2 is a flow chart of a method for a multi-angle resistance welding apparatus according to an embodiment of the present invention;
the reference numerals in fig. 1 are: 1. welding a mechanical arm; 2. a welding workbench; 3. a multi-angle resistance welding equipment base; 4. a resistor transmission device; 5. a multi-angle resistance welding gun set; 6. an adjusting device of the multi-angle resistance welding gun;
the reference numerals in fig. 2 are: s100, a step 100; s200, step 200; s300, step 300; s400, step 400; s500, step 500.
Detailed Description
In order to further describe the technical means and effects adopted by the invention to achieve the preset aim, the following detailed description is given below of a multi-angle resistance welding device according to the invention, which is specific to the implementation, structure, characteristics and effects thereof, with reference to the accompanying drawings and the preferred embodiments. In the following description, different "one embodiment" or "another embodiment" means that the embodiments are not necessarily the same. Furthermore, the particular features, structures, or characteristics of one or more embodiments may be combined in any suitable manner.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
The embodiment of the invention provides multi-angle resistance welding equipment, which comprises a resistance welding equipment body, wherein a welding pressure monitoring and analyzing module is further arranged on the resistance welding equipment body and is used for detecting and analyzing the welding pressure condition when the resistance welding equipment body is used for welding a resistance, so that the welding pressure monitoring and analyzing module comprises a welding pressure collector, a resistance welding gun pose adjusting mechanism and a welding pressure monitoring and analyzing controller, wherein the welding pressure collector is connected with the welding pressure monitoring and analyzing controller, the welding pressure monitoring and analyzing controller is used for data processing and machine control, the chip type is an FPGA (field programmable gate array) and is used for receiving the information of the welding pressure collector and controlling the resistance welding gun pose adjusting mechanism.
The following specifically describes a specific scheme of the multi-angle resistance welding device provided by the invention with reference to the accompanying drawings.
Referring to fig. 1, a block diagram of a multi-angle resistance welding apparatus according to an embodiment of the present invention is shown, the resistance welding apparatus body includes: the welding machine comprises a welding mechanical arm 1, a welding workbench 2, a multi-angle resistance welding equipment base 3, a resistance transmission device 4, a multi-angle resistance welding gun set 5 and a multi-angle resistance welding gun adjusting device 6.
The signal output end of the welding pressure collector is connected with the signal input end of the welding pressure monitoring analysis controller, the signal output end of the welding pressure monitoring analysis controller is connected with the signal input end of the resistance welding gun pose adjusting mechanism, and the resistance welding gun pose adjusting mechanism is used for being assembled and connected with the resistance welding gun and adjusting the pose state of the resistance welding gun. The welding pressure collector is used for obtaining the welding pressure when the resistance welding gun is in contact with the resistance and outputting the welding pressure to the welding pressure monitoring and analyzing controller.
In the embodiment of the present invention, the resistance welding gun is a resistance welding gun on the multi-angle resistance welding gun set 5, and in other embodiments, the resistance welding gun can be a single resistance welding gun with adjustable angle. In the embodiment of the invention, the welding pressure collector is a stress sensor, and in other embodiments, other sensors can collect welding pressure. In the embodiment of the invention, the resistance welding gun pose adjusting mechanism is an adjusting device 6 of the multi-angle resistance welding gun, and the angle adjustment of the multi-angle resistance welding gun can be realized through a manipulator in the embodiment of the invention. The welding pressure monitoring and analyzing module is composed of a welding pressure collector, a resistance welding gun pose adjusting mechanism and a welding pressure monitoring and analyzing controller.
In the embodiment of the invention, a welding pressure collector is arranged on an electric welding gun so as to collect data in the welding process by utilizing the welding pressure collector attached to the resistance welding gun at each angle on a welding pressure monitoring and analyzing module, and the collected welding pressure is output to a welding pressure monitoring and analyzing controller to obtain a welding pressure abnormal value; and outputting a control instruction to a resistance welding gun pose adjusting mechanism according to the abnormal welding pressure value, wherein the control instruction is used for controlling the action of the resistance welding gun so as to adjust the resistance welding gun to an optimal welding angle.
Referring to fig. 2, a flowchart of a method for analyzing welding pressure conditions when a resistance welding gun is in contact with a resistor by using a welding pressure monitoring analysis controller in a multi-angle resistance welding device according to an embodiment of the invention is shown, the method includes the following steps:
and step S100, preprocessing the welding pressure to obtain a resistance welding pressure value.
The purpose of the embodiment of the invention is to optimize the comprehensive coverage and the better welding quality of the resistance welding links corresponding to the traditional resistance welding equipment, particularly, a welding gun has a certain degree of contact with a resistance in the process of welding the resistance, and under the contact, the position of the resistance can deviate to a certain degree so as to cause the change of a welding result, so that the invention collects data in the welding process by utilizing a welding pressure collector attached to the resistance welding gun at each angle on a welding pressure monitoring and analyzing module, analyzes the collected data at multiple angles, and further correspondingly adjusts the welding gun at different angles, thereby being more suitable for the welding of the current resistance element. In the embodiment of the invention, the welding pressure collector is a mechanical sensor attached to the resistance welding gun. And then the welding pressure when the resistance welding gun is contacted with the resistance is obtained through the welding pressure collector.
The invention specifically utilizes the mechanical real-time data acquired by the mechanical sensors corresponding to the welding guns on each angle to predict the stress degree of the resistance welding gun on the current angle at the next moment, and then adjusts the angles of the resistance welding gun under the current angles according to the prediction results.
In the resistance welding process, the analysis and prediction of the stress data of each welding gun are processed based on a moving average algorithm, and in the complex change, the data acquired by the sensor has certain noise data, so when the resistance welding stress data of different angles of the next welding moment at the current welding moment is predicted by using the moving average prediction algorithm, the noise data exists in the adopted historical data, and the deviation value of the noise data relative to the integral normal data is generally larger, so that the influence of the noise component on the stress data of the resistance at the current angle at the next moment by the moving average algorithm is extremely large, the prediction result is inaccurate, and errors are easy to adjust when the resistance at the current angle at the next moment is subjected to angle adjustment, and the integral welding result is abnormal.
Therefore, before the resistance welding prediction angle adjustment for each angle is performed, it is necessary to perform corresponding data acquisition for each angle of the resistance welding gun at the start of resistance welding, specifically, taking the a-th resistance welding gun as an example,wherein->Indicating the total number of all resistance guns in the multi-angle resistance welding gun set. Stress data time sequence set of resistance from resistance welding corresponding to a resistance welding gun>Specifically, the welding pressure time sequence set of the resistance from the beginning of the resistance welding corresponding to the a-th resistance welding gun is shown as +.>The method is specifically as follows:
wherein,is->Resistance weldingThe actual stress data acquired by the stress sensor corresponding to the 1 st moment of history in the welding process of the gun for resistance is +.>Welding pressure at time 1 of the resistance welding gun; />Is->The actual stress data collected by the stress sensor corresponding to the 2 nd moment of history in the process of resistance welding by the resistance welding gun is +.>Welding pressure at time 2 of the resistance welding gun; />Is->The actual stress data acquired by the stress sensor corresponding to the t th moment of the history in the process of resistance welding by the resistance welding gun is +.>Welding pressure at time t of the resistance welding gun; />Is->The actual stress data acquired by the stress sensor corresponding to the historical T moment in the process of resistance welding by the resistance welding gun is +.>Welding pressure at time T of each resistance welding gun. Wherein (1)>Wherein->Indicating the current time of resistance welding.
It should be noted that, since the moving average prediction is based on time stationarity of data, and the welding pressure data corresponding to the resistance welding gun is not necessarily a time stationarity model during resistance welding, the welding pressure needs to be preprocessed. The resistance welding pressure values mentioned later are all data after the time stabilization treatment by the self-adaptive step difference method.
And step 200, analyzing according to the resistance welding pressure values at adjacent moments in the resistance welding pressure value sequence to obtain the stability of the resistance welding pressure value sequence.
According to step S100, the welding pressure corresponding to each resistance welding gun in the multi-angle resistance welding gun set 5 is processed, so that all resistance welding pressure values corresponding to all resistance welding guns at the current moment can be obtained.
At the firstThe first +.>Resistance welding pressure value of force sensor of each resistance welding gun is carried out +.>Resistance welding pressure value at each instant->Before the prediction of (2), the selection of the base data amount of the prediction is needed first, because in the conventional moving average prediction algorithm, the selected base number is the sameThe number of the data is ideally not affected by the noise data, so the data is of fixed size, and in the embodiment, certain noise data may exist, so the appropriate number of basic data pairs need to be selected when the prediction is performedThe data at each instant is processed. The invention does->The number selection process of the prediction basis data at each moment is the utilization data +.>Before the moment->The stability analysis of the individual data is carried out, and the front +.>The individual data is processed as base data. In the embodiment of the invention, set +.>And the value of (2) is 20, and in other embodiments, the value is adjusted by an implementer according to the actual situation. That is, the first 20 at time T constitute the base data, which will be described by +.>The sequence of individual resistance welding pressure values is referred to as a resistance welding pressure value sequence.
Therefore, further, according to the resistance welding pressure values at adjacent moments in the resistance welding pressure value sequence, analysis is performed to obtain the stability of the resistance welding pressure value sequence, specifically: analyzing according to the difference of the resistance welding pressure values at adjacent moments in the resistance welding pressure value sequence to obtain a characteristic value of each resistance welding pressure value; and determining the stability of the resistance welding pressure value sequence by combining the fluctuation condition of the characteristic value of the resistance welding pressure value.
The method for acquiring the characteristic value comprises the following steps: taking the resistance welding pressure value at any moment as a target pressure value; taking the ratio of the resistance welding pressure value at the moment before the target pressure value and the target pressure value as a first ratio; taking the ratio of the target pressure value and the resistance welding pressure value at the later moment as a second ratio; and taking the absolute value of the difference value of the first ratio and the second ratio as the characteristic value of the target pressure value. And acquiring a characteristic value of each resistance welding pressure value.
According to the invention, the characteristic value corresponding to the resistance welding pressure value is obtained by analyzing the original resistance welding pressure value, when the resistance welding pressure value is utilized to calculate, the corresponding strength of the resistance welding gun is relatively large when the resistance welding gun is likely to weld at a certain section of continuous time, and certain data size differences exist among other resistance welding pressure values in the resistance welding pressure value sequence, wherein the situation belongs to the normal situation, but when the resistance welding pressure value under the situation is utilized to calculate the variation, the normal data section is judged to be abnormal, so that the integral variation coefficient is relatively large, and the actual stability calculation cannot be effectively performed. Therefore, the invention firstly calculates the characteristic value of each resistance welding pressure value, and the characteristic value is calculated by utilizing a difference method, because abnormal noise data usually appear, the abnormal noise data are unit impulse responses, namely, no continuity exists, the larger the neighborhood difference is, and the continuity of the neighborhood is generally provided for normal data, so the characteristic value is smaller.
Therefore, firstly, the characteristic value of each resistance welding pressure value is calculated, and further, the stable value of the resistance welding pressure value sequence is determined by combining the fluctuation condition of the characteristic value of the resistance welding pressure value. The calculation formula of the stability is as follows:
the method comprises the steps of carrying out a first treatment on the surface of the Wherein (1)>Stability for the sequence of resistance welding pressure values; e is a natural constant; />The number of resistance welding pressure values in the sequence of resistance welding pressure values; />For the resistance welding pressure value sequence +.>Characteristic values of the resistance welding pressure values; />Is the average of the characteristic values of all the resistance welding pressure values in the resistance welding pressure value sequence.
The calculation logic of the stability formula is to use the variation coefficient to perform allThe purpose of the employed variation coefficient is to change the amount of data in the sequence of resistance welding pressure values in the following steps, so that when the variation coefficient is used for stability calculation, the variation of the amount of the sequence of resistance welding pressure values can be ignored, and thus the stability comparison cannot be performed.
And step S300, adjusting the resistance welding pressure value sequence in combination with the stability to obtain a stable welding pressure value sequence.
Can be relative to the firstBefore the moment->All ∈s corresponding to the moment>Performing stability calculation analysis on the resistance welding pressure values, and indicating +.>All +.>There may be a certain amount of noise data in the individual resistance welding pressure values, with this +.>When the resistance welding pressure values are subjected to moving average prediction, the possibility of deviation of a prediction result exists, and more resistance welding pressure values are needed to be used as a basic data set to ensure the accuracy of prediction; the opposite is true.
And when the stability is smaller than a preset stability threshold value, adding a preset number of resistance welding pressure values in the resistance welding pressure value sequence to obtain a stability welding pressure value sequence. In the embodiment of the invention, the preset value of the stability threshold is 0.8, the preset number of values is 3, and in other embodiments, the value is adjusted by an implementer according to actual conditions.
When the stability is less than a preset stability threshold, an adjustment is required. The adjusting process is as follows: in the first placeGradually adding preset number of resistance welding pressure values into the resistance welding pressure value sequence before each moment, then re-calculating the stability of the basic data set added with more historical data, and performing threshold judgment until the threshold judgment is met, wherein the number of the basic data sets corresponding to the regulated resistance welding pressure values is->That is, the number of stable welding pressure value sequences is +.>. For example, there are 9 total resistance welding pressure values: 1. 2, 3, 4, 5, 6, 7, 8, 9, if +.>When the number is 3, the corresponding resistance welding pressure value sequence is {7, 8, 9}, when the stability of the resistance welding pressure value sequence is less than 0.8, the preset number of resistance welding pressure values are added in the resistance welding pressure value sequence to obtain the stable welding pressure value sequence, namely, the first 3 resistance welding pressure values are added in the resistance welding pressure value sequence, and the corresponding stable welding pressure value sequence is {4, 5, 6, 7, 8, 9}.
To this end, proceed withNo. H of resistance welding gun>Predicted data +.>And (5) the preparation of the corresponding prediction basic data set is finished during prediction.
And step S400, analyzing the possibility that the resistance welding pressure value is abnormal noise and the data trend condition of the resistance welding pressure value in the stable welding pressure value sequence, and determining the pressure weight of the resistance welding pressure value.
By the firstResistance welding pressure values in the sequence of stable welding pressure values of the individual resistance welding guns, for +.>Predicted data +.>Before the prediction, the weight of the data different from the data set needs to be defined, and because abnormal noise data may exist in the basic data set as described above, in the process of calculating the prediction, the weight of the different resistance welding pressure values needs to be defined, so that the overall prediction of the noise data in the process of prediction is smaller, and the importance of the normal data in the process of performing the prediction is improved.
Analyzing the possibility that the resistance welding pressure value is abnormal noise and the data trend situation of the resistance welding pressure value in the stable welding pressure value sequence, and determining the pressure weight of the resistance welding pressure value, and specifically: determining the abnormal possibility of each resistance welding pressure value according to the possibility that the resistance welding pressure value in the stable welding pressure value sequence is abnormal noise; determining the data universality trend of each resistance welding pressure value according to the data trend condition of the resistance welding pressure value; and taking the normalized value of the ratio of the data universality trend and the abnormality probability as the pressure weight of the resistance welding pressure value.
Wherein, according to the possibility that the resistance welding pressure value is abnormal noise in the stable welding pressure value sequence, determining the abnormal possibility of each resistance welding pressure value, wherein the calculation formula of the abnormal possibility is as follows:
the method comprises the steps of carrying out a first treatment on the surface of the Wherein (1)>To stabilize the abnormal probability of the ith resistance welding pressure value in the sequence of welding pressure values; />The ith resistance welding pressure value in the sequence of stable welding pressure values; />The (i+1) resistance welding pressure value in the sequence of stable welding pressure values; />The i-1 resistance welding pressure value in the sequence of stable welding pressure values; />In order to stabilize the welding pressure value sequence, in addition to the resistance welding pressure value +.>The number of other resistance welding pressure values; />For stabilizing the resistance welding pressure value in the sequence of welding pressure values +.>Total number of occurrences; />In order to stabilize the welding pressure value sequence, in addition to the resistance welding pressure value +.>External->The number of times the data appears in the sequence of steady pressure values; />The number of resistance welding pressure values in the sequence of stabilizing pressure values; />Is the mean value of the resistance welding pressure values in the steady pressure value sequence.
When the weight calculation is carried out, the abnormal noise data needs to be suppressed, so the invention is applicable to allThe magnitude of each resistance welding pressure value is +.>Judging the +.f in the sequence of steady pressure values based on multiple characteristics of the data of (2)>Resistance welding pressure value->Is the possibility of abnormal data, in particular, the +.>Resistance welding pressure valueIn the anomaly analysis process of (2), the invention adopts the difference of the neighborhood size +.>The calculation, the larger this value, indicates +.>Compared with the data of the neighborhood, the resistance welding pressure values have obvious difference in size, and most of noise abnormal data are impulse response and have no continuity; normal data has certain continuity, so the corresponding neighborhood size difference should be smaller. Secondly, the difference calculation of the global appearance frequency is carried out, when the data is normal data, the stable appearance frequency should be obeyed in the global, so the invention can ensure that the appearance frequency of all resistance welding pressure values with different magnitudes in the stable pressure value sequence in the global is equal to the +.>The frequency of occurrence of the individual resistance welding pressure values in the global is calculated as a difference value, the greater the value, which indicates the +.>The more anomalous the individual resistance weld pressure values. It should be noted that this part is to prevent the first +.>The data is just the correction of special cases at the junction of different trends. Finally, calculating the average value of the global data, wherein the local trend is different in the welding process, but all the whole welding processes are subjected to welding with the strength under a certain interval, so the method is>The larger the average difference between the individual resistance welding pressure values and the magnitudes of all the resistance welding pressure values as a whole, the higher the likelihood that they are abnormal data.
According to the data trend condition of the resistance welding pressure values, determining the data universality trend of each resistance welding pressure value, wherein the calculation formula of the data universality trend is as follows:
the method comprises the steps of carrying out a first treatment on the surface of the Wherein (1)>The data universality trend of the ith resistance welding pressure value in the stable welding pressure value sequence is that; />The number of resistance welding pressure values in the sequence of stabilizing pressure values; />The ith resistance welding pressure value in the sequence of stable welding pressure values; />The method comprises the steps of stabilizing the I-j resistance welding pressure values in a welding pressure value sequence; e is a natural constant.
Resistance welding pressure values of different trends for the firstWhen the resistance welding pressure values are predicted, the reference values are different, and in the welding process of the resistance, sections with different forces can exist, and the i resistance welding pressure value in the stable welding pressure value sequence is firstly required to be judged to be the i resistance welding pressure value and the i resistance welding pressure value to be predicted>Whether or not the data belong to the same trend interval, wherein +.>The probability of the data being of +.>The trend interval corresponding to the resistance welding pressure value, so the present invention is achieved by using the +.>Resistance welding pressure value and from +.>Calculating the difference value of the data in the interval of the data, wherein the smaller the difference value is, the description of the +.>The greater the likelihood that the individual resistance welding pressure value belongs to the current trend interval, the more the +.>The duration of the data, the invention therefore uses the function +.>As a weight, and +.>The closer the data, the greater the likelihood of belonging to a section, and vice versa, the more the +.>Data general trend of individual data +.>The larger this value, the description +.>Data and->Data belonging to a trend intervalThe greater the likelihood. Finally use of->Possibility of abnormality of individual data +.>Data commonality trend +.>Calculating the predicted weight of each data, wherein the logic is as follows: first->Data and->The greater the likelihood that the data belongs to one data trend, the greater the corresponding predictive weight should be, and the greater the likelihood that the data is abnormal, the smaller the corresponding pressure weight should be.
After the anomaly possibility and the data versatility trend are obtained respectively, the normalized value of the ratio of the data versatility trend and the anomaly possibility is used as the pressure weight of the resistance welding pressure value.
The method is used for the firstAll +.>The data are processed to obtain all +.>And the pressure weight corresponding to the data.
Step S500, based on the pressure weight, carrying out weighted averaging on the data in the stable welding pressure value sequence to obtain a welding pressure predicted value; and determining the optimal welding angle according to the predicted welding pressure value.
For stable welding pressure value sequenceAll of the columnsThe data are weighted, and all resistance welding pressure values in the stable welding pressure value sequence and the pressure weights corresponding to all resistance welding pressure values are utilized to carry out the +.>No. H of resistance welding gun>Predicted welding pressure at time ∈>The specific method is as follows:
the method comprises the steps of carrying out a first treatment on the surface of the Wherein (1)>A predicted value of the welding pressure; />A pressure weight for stabilizing an ith resistance welding pressure value in the sequence of welding pressure values; />The ith resistance welding pressure value in the sequence of stable welding pressure values; />To stabilize the number of resistance welding pressure values in the sequence of welding pressure values.
By weighting and averaging the resistance welding pressure values in the sequence of stable welding pressure values, inaccuracy in predicting the welding pressure predicted value due to noise is reduced.
To this end, the firstNo. H of resistance welding gun>Predicted data +.>And (5) finishing prediction.
By means of the method, the stress data of the resistance welding gun at the next moment corresponding to all angles are predicted, and the welding pressure predicted value of the resistance welding gun at the next moment corresponding to all angles can be obtained.
In the embodiment of the invention, the average value of all the resistance welding pressure values before the current moment is calculated as the preset pressure value, and in other embodiments, the preset pressure value can be set by an implementer according to actual conditions or experience values. It should be noted that, the method for obtaining the optimal welding angle may be implemented through machine learning, and will not be described herein.
When the predicted welding pressure value is smaller than or equal to the preset pressure value, the angle of the resistance welding gun does not need to be regulated and controlled.
When the predicted welding pressure value is larger than the preset pressure value, determining the optimal welding angle according to the predicted welding pressure value, and realizing the subsequent adjustment of the angle of the resistance welding gun.
Determining an optimal welding angle according to the predicted welding pressure value, and specifically: and (3) inputting a welding pressure predicted value and a preset pressure value by utilizing an ant colony algorithm to obtain an optimal welding angle.
Further, a control instruction is output to the resistance welding gun pose adjusting mechanism according to the optimal welding angle, and the control instruction is used for controlling the resistance welding gun to act so as to adjust the resistance welding gun to the optimal welding angle. The resistance welding gun pose adjusting mechanism can be a manipulator to realize the welding angle of the resistance welding gun; the welding gun can also be a traction device for adjusting the pose so as to realize the welding angle of the resistance welding gun; the optimal welding angle can be output to the data display screen, and the angle of the resistance welding gun can be adjusted by an operator according to the optimal welding angle on the data display screen.
In summary, the present invention relates to the field of resistance welding technology. The embodiment of the invention provides multi-angle resistance welding equipment, which comprises a welding pressure monitoring and analyzing module. The welding pressure monitoring and analyzing module comprises: the welding pressure monitoring and analyzing device comprises a welding pressure collector, a resistance welding gun pose adjusting mechanism and a welding pressure monitoring and analyzing controller. The welding pressure monitoring and analyzing controller is used for analyzing the welding pressure when the resistance welding gun is in contact with the resistance to obtain a welding pressure predicted value and a corresponding optimal welding angle, and outputting a control instruction through the resistance welding gun pose adjusting mechanism to control the resistance welding gun to act so as to adjust the resistance welding gun to the optimal welding angle. The invention achieves more efficient and accurate resistance welding.
It should be noted that: the sequence of the embodiments of the present invention is only for description, and does not represent the advantages and disadvantages of the embodiments. The processes depicted in the accompanying drawings do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.
In this specification, each embodiment is described in a progressive manner, and identical and similar parts of each embodiment are all referred to each other, and each embodiment mainly describes differences from other embodiments.
Claims (7)
1. The utility model provides a multi-angle resistance welding equipment, includes resistance welding equipment body, resistance welding equipment body includes resistance welding rifle, its characterized in that, resistance welding equipment is still including welding pressure monitoring analysis module, welding pressure monitoring module installs in resistance welding equipment body, welding pressure monitoring analysis module includes: a welding pressure collector, a resistance welding gun pose adjusting mechanism and a welding pressure monitoring analysis controller;
the signal output end of the welding pressure collector is connected with the signal input end of the welding pressure monitoring and analyzing controller, the signal output end of the welding pressure monitoring and analyzing controller is connected with the signal input end of the resistance welding gun pose adjusting mechanism, and the resistance welding gun pose adjusting mechanism is used for being assembled and connected with a resistance welding gun and adjusting the pose state of the resistance welding gun;
the welding pressure collector is used for obtaining the welding pressure when the resistance welding gun is in contact with the resistance and outputting the welding pressure to the welding pressure monitoring analysis controller; the welding pressure monitoring and analyzing controller preprocesses the welding pressure to obtain a resistance welding pressure value; analyzing according to the resistance welding pressure values at adjacent moments in the resistance welding pressure value sequence to obtain the stability of the resistance welding pressure value sequence; adjusting the resistance welding pressure value sequence in combination with the stability to obtain a stable welding pressure value sequence; analyzing the possibility that the resistance welding pressure value is abnormal noise and the data trend condition of the resistance welding pressure value in the stable welding pressure value sequence, and determining the pressure weight of the resistance welding pressure value; based on the pressure weight, carrying out weighted averaging on the data in the stable welding pressure value sequence to obtain a welding pressure predicted value; determining an optimal welding angle according to the predicted welding pressure value; outputting a control instruction to the resistance welding gun pose adjusting mechanism according to the optimal welding angle, wherein the control instruction is used for controlling the resistance welding gun to act so as to adjust the resistance welding gun to the optimal welding angle;
wherein, the analysis of the probability that the resistance welding pressure value is abnormal noise and the data trend situation of the resistance welding pressure value in the stable welding pressure value sequence, the determination of the pressure weight of the resistance welding pressure value comprises the following steps:
determining the abnormal possibility of each resistance welding pressure value according to the possibility that the resistance welding pressure value in the stable welding pressure value sequence is abnormal noise;
determining the data universality trend of each resistance welding pressure value according to the data trend condition of the resistance welding pressure value;
taking a normalized value of the ratio of the data universality trend to the abnormality probability as a pressure weight of a resistance welding pressure value;
wherein determining the likelihood of abnormality for each resistance welding pressure value based on the likelihood that the resistance welding pressure value is abnormal noise in the sequence of stable welding pressure values comprises:
the calculation formula of the anomaly possibility is as follows:
the method comprises the steps of carrying out a first treatment on the surface of the Wherein (1)>To stabilize the abnormal probability of the ith resistance welding pressure value in the sequence of welding pressure values; />The ith resistance welding pressure value in the sequence of stable welding pressure values; />The (i+1) resistance welding pressure value in the sequence of stable welding pressure values; />The i-1 resistance welding pressure value in the sequence of stable welding pressure values; />In order to stabilize the welding pressure value sequence, in addition to the resistance welding pressure value +.>The number of other resistance welding pressure values; />For stabilizing the resistance welding pressure value in the sequence of welding pressure values +.>Total number of occurrences;in order to stabilize the welding pressure value sequence, in addition to the resistance welding pressure value +.>External->The number of times the data appears in the sequence of steady pressure values; />The number of resistance welding pressure values in the sequence of stabilizing pressure values; />The average value of the resistance welding pressure values in the stable pressure value sequence;
wherein, according to the data trend condition of resistance welding pressure value, confirm the data commonality trend of every resistance welding pressure value, include:
the calculation formula of the data universality trend is as follows:
the method comprises the steps of carrying out a first treatment on the surface of the Wherein (1)>The data universality trend of the ith resistance welding pressure value in the stable welding pressure value sequence is that; />The number of resistance welding pressure values in the sequence of stabilizing pressure values; />The ith resistance welding pressure value in the sequence of stable welding pressure values; />The method comprises the steps of stabilizing the I-j resistance welding pressure values in a welding pressure value sequence; e is a natural constant.
2. The multi-angle resistance welding apparatus according to claim 1, wherein said analyzing based on said resistance welding pressure values at adjacent times in a sequence of resistance welding pressure values to obtain stability of the sequence of resistance welding pressure values comprises:
analyzing according to the difference of the resistance welding pressure values at adjacent moments in the resistance welding pressure value sequence to obtain a characteristic value of each resistance welding pressure value; and determining the stability of the resistance welding pressure value sequence by combining the fluctuation condition of the characteristic value of the resistance welding pressure value.
3. The multi-angle resistance welding apparatus according to claim 2, wherein the analyzing according to the differences of the resistance welding pressure values at adjacent times in the sequence of resistance welding pressure values to obtain the characteristic value of each resistance welding pressure value comprises:
taking the resistance welding pressure value at any moment as a target pressure value; taking the ratio of the resistance welding pressure value at the moment before the target pressure value and the target pressure value as a first ratio; taking the ratio of the target pressure value and the resistance welding pressure value at the later moment as a second ratio; and taking the absolute value of the difference value of the first ratio and the second ratio as the characteristic value of the target pressure value.
4. The multi-angle resistance welding apparatus according to claim 2, wherein said determining stability of the sequence of resistance welding pressure values in combination with fluctuation of the characteristic values of the resistance welding pressure values comprises:
the stability is calculated according to the following formula:
the method comprises the steps of carrying out a first treatment on the surface of the Wherein (1)>Stability for the sequence of resistance welding pressure values; e is a natural constant; />The number of resistance welding pressure values in the sequence of resistance welding pressure values; />For the first of the series of resistance welding pressure valuesCharacteristic values of the resistance welding pressure values; />Is the average of the characteristic values of all the resistance welding pressure values in the resistance welding pressure value sequence.
5. The multi-angle resistance welding apparatus according to claim 1, wherein said determining an optimal welding angle based on the welding pressure prediction value comprises:
when the predicted welding pressure value is larger than the preset pressure value, the ant colony algorithm is utilized to input the predicted welding pressure value and the preset pressure value, and the optimal welding angle is obtained.
6. The multi-angle resistance welding apparatus of claim 1, wherein said adjusting said sequence of resistance welding pressure values in combination with said stability comprises:
and when the stability is smaller than a preset stability threshold, adding a preset number of resistance welding pressure values in the resistance welding pressure value sequence to obtain a stable welding pressure value sequence.
7. The multi-angle resistance welding apparatus according to claim 1, wherein said preprocessing of said welding pressure to obtain a resistance welding pressure value comprises:
and preprocessing the welding pressure by using a self-adaptive step difference method to obtain a resistance welding pressure value.
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| CN116900449A (en) * | 2023-08-21 | 2023-10-20 | 广州虹科电子科技有限公司 | Welding quality monitoring method and system based on signal fusion |
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| CN101323046A (en) * | 2007-06-14 | 2008-12-17 | 发那科株式会社 | Spot welding system and method for adjusting welding-gun closing speed |
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