CN117961294A - Laser beam welding method and system - Google Patents
Laser beam welding method and system Download PDFInfo
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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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/21—Bonding by welding
- B23K26/24—Seam welding
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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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/12—Working by laser beam, e.g. welding, cutting or boring in a special atmosphere, e.g. in an enclosure
- B23K26/123—Working by laser beam, e.g. welding, cutting or boring in a special atmosphere, e.g. in an enclosure in an atmosphere of particular gases
-
- 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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/70—Auxiliary operations or equipment
- B23K26/702—Auxiliary equipment
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Abstract
The invention relates to the technical field of laser welding, and particularly provides a laser beam welding method and a laser beam welding system, wherein the method comprises the following steps: acquiring image data to obtain the cleanliness of a region to be welded and the width of a welding seam; judging whether welding operation can be performed or not according to the cleanliness, and determining the diameter of a laser beam according to the width of a welding line; determining the running power and pulse frequency of a laser beam based on the depth data of the region to be welded obtained by ultrasonic waves; collecting material properties to judge whether to start the gas protection device; acquiring thermal imaging data of a region to be welded based on a thermal infrared imager, and judging whether the interior of the region to be welded is welded in a melting way or not; and collecting the image data after the primary welding is finished, analyzing the image data after the primary welding is finished, and judging whether the welding result is qualified or not. The invention solves the problems of fixed parameter setting, lack of intelligent regulation and feedback mechanism and large amount of dependence on technicians existing in the traditional laser welding technology, and improves the welding quality, efficiency and stability.
Description
Technical Field
The invention relates to the technical field of laser welding, in particular to a laser beam welding method and a laser beam welding system.
Background
The laser beam welding uses a laser beam with high energy density to intensively heat a welding area to instantly reach a temperature above a melting point, thereby realizing melting. The laser beam is focused via an optical system into a highly concentrated beam that impinges on the weld area in a precise manner, melts the metal and forms a weld.
There are some limitations of the current conventional laser welding technology, mainly in the fixability of parameter setting and the lack of intelligent adjustment function. Conventional laser welding systems generally employ fixed parameter settings, such as a fixed beam diameter, pulse interval, energy density, etc., which cannot be automatically adjusted according to actual welding conditions, so that the welding effect is difficult to reach an optimal state under the welding requirements of different welding seams and different materials. In the traditional laser welding process, the intelligent adjusting function is lacked, and the self-adaptive adjustment can not be carried out according to the real-time welding condition. This means that during the welding process, the welding cannot be adjusted in time according to the shape of the welding area, the characteristics of the material and the change of the welding conditions, which results in unstable welding effect and even occurrence of welding defects. Furthermore, due to the lack of a feedback adjustment mechanism, manual control by a technician is required during the welding process. The experience and skill level of the technician has an important impact on welding quality and requires extensive time and effort to debug and optimize, which increases production costs and reduces production efficiency.
Accordingly, there is a need for a laser beam welding method and system that solves the problems of the prior art.
Disclosure of Invention
In view of the above, the invention provides a laser beam welding method and system, which aim to solve the problems of fixed parameter setting, lack of intelligent regulation function, lack of feedback regulation mechanism, lower welding quality and lower production efficiency in the current laser welding technology.
In one aspect, the present invention provides a laser beam welding method comprising:
Collecting image data of a welding area, and analyzing the image data to obtain the cleanliness of the area to be welded and the width of a welding seam;
Judging whether welding operation can be performed or not according to the cleanliness, and determining the diameter of a laser beam according to the width of the welding line when the area to be welded is determined to be qualified;
When the diameter of the laser beam is determined and welding operation can be carried out, moving a laser to the initial position of the area to be welded, acquiring depth data of the area to be welded based on ultrasonic waves, and determining the running power and the pulse frequency of the laser beam according to the depth data;
collecting material properties of the area to be welded, and judging whether to start a gas protection device according to the material properties; when the area to be welded is judged to belong to the easily-oxidizable material, starting the gas protection device and determining a gas supply rate;
after determining whether to start the gas protection device, starting the laser to carry out laser welding on the to-be-welded area, acquiring thermal imaging data of the to-be-welded area based on a thermal infrared imager in the welding process, and judging whether the inside of the to-be-welded area is welded in a melting manner according to the thermal imaging data; when the interior of the area to be welded is judged to be not welded in a melting way, the pulse frequency of the laser beam is adjusted, and the operation is continued at the adjusted pulse frequency;
Collecting image data after one-time welding, analyzing the image data after one-time welding and judging whether a welding result is qualified or not; and when the welding result is judged to be unqualified, performing secondary welding on the area after the primary welding is finished, acquiring the area of an unsuccessful welding area when performing secondary welding, and correcting the running power of the laser beam according to the area occupation ratio of the unsuccessful welding area.
Further, judging whether welding operation can be performed according to the cleanliness, and when determining that the area to be welded is qualified, determining the diameter of the laser beam according to the width of the welding seam includes:
Comparing the cleanliness J with a preset standard cleanliness J0, and judging whether the area to be welded can be subjected to welding operation or not according to a comparison result;
when J is more than J0, judging that the area to be welded is qualified and performing welding operation;
when J is less than or equal to J0, judging that dirt, impurities or residues exist in the area to be welded, wherein the cleanliness is unqualified, and the welding operation cannot be performed;
when the to-be-welded area is determined to be qualified, the welding seam width K is respectively compared with a first preset welding seam width K1 and a second preset welding seam width K2, K1 is smaller than K2, and the diameter of the laser beam is determined according to the comparison result;
When K is less than or equal to K1, determining the diameter of the laser beam as a first preset diameter D1;
when K1 is more than K and less than or equal to K2, determining the diameter of the laser beam as a second preset diameter D2;
when K2 is less than K, determining the diameter of the laser beam as a third preset diameter D3;
Wherein, 0 < D1 < D2 < D3.
Further, when determining the operating power and the pulse frequency of the laser beam according to the depth data, the method includes:
Comparing the depth data H with a first preset depth H1 and a second preset depth H2 which are preset respectively, wherein H1 is smaller than H2, and determining the running power and the pulse frequency of the laser beam according to the comparison result;
when H is less than or equal to H1, determining the operation power of the laser beam as a first preset operation power P1, and determining the pulse frequency of the laser beam as a third preset pulse frequency M3;
When H1 is more than H and less than or equal to H2, determining the running power of the laser beam as second preset running power P2, and determining the pulse frequency of the laser beam as second preset pulse frequency M2;
When H2 is less than H, determining the operation power of the laser beam as a third preset operation power P3, and determining the pulse frequency of the laser beam as a first preset pulse frequency M1;
Wherein, P1 is more than 0 and P2 is more than 3, M1 is more than 0 and M2 is more than 3.
Further, when judging whether to open the gas protection device according to the material property, the method includes:
Acquiring the material properties of the region to be welded according to the image data of the region to be welded;
When the area to be welded belongs to an oxidizable material, starting the gas protection device and determining the gas supply rate according to the depth data H;
and when the area to be welded belongs to a material which is not easy to oxidize, the gas protection device is not started.
Further, when it is determined to turn on the gas protection device and to determine the gas supply rate based on the depth data H, it includes:
when H is less than or equal to H1, determining the gas supply rate of the gas protection device as a first preset gas supply rate V1;
When H1 is more than H and less than or equal to H2, determining the gas supply rate of the gas protection device to be a second preset gas supply rate V2;
when H2 is less than H, determining the gas supply rate of the gas protection device to be a third preset gas supply rate V3;
Wherein, V1 is more than 0 and V2 is more than 0 and V3.
Further, acquiring thermal imaging data of the to-be-welded area based on the thermal infrared imager in the welding process, and judging whether the inside of the to-be-welded area is melted and welded according to the thermal imaging data, wherein the method comprises the following steps:
obtaining the melting depth R of the region to be welded according to the thermal imaging data, comparing the melting depth R with the depth data H, and judging whether the interior of the region to be welded is melted and welded according to a comparison result;
When R is less than H, judging that the interior of the area to be welded is not welded in a melting way, acquiring depth difference delta H between the depth data H and the melting depth R, wherein delta H=H-R, and adjusting the pulse frequency of the laser beam according to the depth difference delta H so as to continue to operate at the adjusted pulse frequency;
when R is more than or equal to H, the internal fusion welding of the area to be welded is judged, and the pulse frequency of the laser beam is not adjusted.
Further, when the i-th preset pulse frequency Mi is selected as the pulse frequency of the laser beam and it is determined to adjust the pulse frequency Mi of the laser beam, i=1, 2,3, including:
comparing the depth difference delta H with a first preset depth difference delta H1 and a second preset depth difference delta H2, wherein delta H1 is smaller than delta H2, and selecting an adjustment coefficient according to the comparison result to adjust the pulse frequency Mi of the laser beam to obtain the adjusted pulse frequency;
When delta H is less than or equal to delta H1, selecting a first preset adjustment coefficient A1 to adjust the pulse frequency Mi of the laser beam, and obtaining the adjusted pulse frequency Mi;
when delta H1 is less than delta H and less than or equal to delta H2, selecting a second preset adjustment coefficient A2 to adjust the pulse frequency Mi of the laser beam, and obtaining the adjusted pulse frequency Mi;
when delta H2 is smaller than delta H, selecting a third preset adjustment coefficient A3 to adjust the pulse frequency Mi of the laser beam, and obtaining the adjusted pulse frequency Mi;
wherein A3 is more than 0 and A2 is more than 0 and A1 is more than 1.
Further, collecting image data after one-time welding, analyzing the image data after one-time welding and judging whether the welding result is qualified or not, including:
Judging whether cracking exists on the welding surface after the primary welding is finished according to the image data after the primary welding is finished;
When the welding surface is cracked after the primary welding is finished, judging that the welding result is unqualified, and performing secondary welding;
And when the welding surface is not cracked after one-time welding is finished, judging that the welding result is qualified.
Further, when it is determined that the welding result is not acceptable and the secondary welding is required, the method includes:
Acquiring a cracking area Y, and acquiring a cracking area occupation ratio Z according to the cracking area Y, wherein Z=Y/Y0, and Y0 represents the area of the area to be welded; comparing the area occupation ratio Z with a first preset area occupation ratio Z1 and a second preset area occupation ratio Z2 which are preset respectively, wherein Z1 is smaller than Z2, and determining a correction coefficient according to the comparison result to correct the running power Pn of the laser beam, wherein n=1, 2 and 3;
When Z is less than or equal to Z1, a first preset correction coefficient B1 is selected to correct the operating power Pn of the laser beam, and corrected operating power Pn is obtained;
When Z1 is more than Z and less than or equal to Z2, selecting a second preset correction coefficient B2 to correct the operating power Pn of the laser beam, and obtaining corrected operating power Pn x B2;
When Z2 is less than Z, selecting a third preset correction coefficient B3 to correct the operation power Pn of the laser beam, and obtaining corrected operation power Pn x B3;
Wherein, B1 is more than 0 and B2 is more than 0 and B3 is more than 1.
Compared with the prior art, the invention has the beneficial effects that: the problems of fixed parameter setting, lack of intelligent adjustment and feedback mechanisms and large dependence on technicians existing in the traditional laser welding technology are solved by utilizing the technical means of image data analysis, ultrasonic acquisition of depth data, thermal imaging data acquisition by a thermal infrared imager and the like. The welding process is more intelligent and self-adaptive by collecting image data and material properties of a welding area, judging the welding feasibility based on factors such as cleanliness and weld width, and starting a gas protection device according to material characteristics. And in the welding process, the internal condition of the area to be welded is monitored in real time, whether the welding area is welded in a melting way or not is judged by acquiring thermal imaging data through the thermal infrared imager, and the parameters of the laser beam are dynamically adjusted when the welding is judged to be unqualified, so that the welding quality is ensured. In addition, the secondary welding function is further provided, unqualified welding areas can be corrected and welded after primary welding is finished, welding efficiency and consistency are improved, and welding quality, efficiency and stability are improved.
In another aspect, the present invention further provides a laser beam welding system, configured to apply the above laser beam welding method, including:
The acquisition unit is configured to acquire image data of a welding area, and analyze the image data to acquire the cleanliness and the welding line width of the area to be welded; judging whether welding operation can be performed or not according to the cleanliness, and determining the diameter of a laser beam according to the width of the welding line when the area to be welded is determined to be qualified;
the processing unit is configured to move the laser to the initial position of the area to be welded and acquire depth data of the area to be welded based on ultrasonic waves when the diameter of the laser beam is determined and welding operation can be carried out, and the operation power and the pulse frequency of the laser beam are determined according to the depth data;
The judging unit is configured to judge whether to start the gas protection device according to the material attribute of the area to be welded, which is not acquired; when the area to be welded is judged to belong to the easily-oxidizable material, starting the gas protection device and determining a gas supply rate;
The adjusting unit is configured to start the laser to carry out laser welding on the area to be welded after determining whether the gas protection device is started, collect thermal imaging data of the area to be welded based on a thermal infrared imager in the welding process, and judge whether the interior of the area to be welded is welded in a melting mode according to the thermal imaging data; when the interior of the area to be welded is judged to be not welded in a melting way, the pulse frequency of the laser beam is adjusted, and the operation is continued at the adjusted pulse frequency;
The correction unit is configured to acquire image data after one-time welding, analyze the image data after one-time welding and judge whether a welding result is qualified or not; and when the welding result is judged to be unqualified, performing secondary welding on the area after the primary welding is finished, acquiring the area of an unsuccessful welding area when performing secondary welding, and correcting the running power of the laser beam according to the area occupation ratio of the unsuccessful welding area.
It can be appreciated that the laser beam welding system and method have the same advantages and are not described herein.
Drawings
Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention. Also, like reference numerals are used to designate like parts throughout the figures. In the drawings:
FIG. 1 is a flow chart of a laser beam welding method according to an embodiment of the present invention;
FIG. 2 is a front view of a laser mask for preventing glare during manual welding in an embodiment;
FIG. 3 is a side view of a glare-proof welding laser mask for manual welding in an embodiment;
FIG. 4 is a rear view of a laser mask for preventing glare during manual welding in an embodiment;
fig. 5 is a functional block diagram of a laser beam welding system according to an embodiment of the present invention.
Wherein, 100, the face covers the screen; 200. a video system; 300. ear caps; 400. an intercom system.
Detailed Description
Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other. The invention will be described in detail below with reference to the drawings in connection with embodiments.
Laser beam welding plays an important role in modern manufacturing as a highly efficient, precise welding technique. The metal is heated up to the temperature above the melting point instantly by utilizing the laser beam with high energy density and by highly concentrated heating the welding area, thereby realizing melting and forming the welding seam. However, despite the advantages of laser welding techniques, conventional laser welding systems still have limitations that are mainly reflected in the fixity of the parameter settings, the lack of intelligent tuning functionality, and the lack of feedback tuning mechanisms.
Conventional laser welding systems typically employ fixed parameter settings such as fixed beam diameter, pulse spacing, and energy density. These parameters can't be adjusted automatically according to actual welding conditions, resulting in that the welding effect is difficult to reach the best state under the welding demands of different welding seams and different materials. In the traditional laser welding process, the intelligent adjusting function is lacked, and the self-adaptive adjustment can not be carried out according to the real-time welding condition. This means that during the welding process, the welding cannot be adjusted in time according to the shape of the welding area, the characteristics of the material and the change of the welding conditions, which results in unstable welding effect and even occurrence of welding defects. In addition, due to the lack of a feedback adjustment mechanism, manual control by a technician is required during the welding process. The experience and skill level of the technician has an important impact on welding quality and requires extensive time and effort to debug and optimize, which increases production costs and reduces production efficiency.
In view of these problems with conventional laser welding techniques, it is necessary to design a novel laser beam welding method and system to address the limitations of the current techniques.
Referring to fig. 1, the present embodiment provides a laser beam welding method, including:
S100: and acquiring image data of the welding area, and analyzing the image data to acquire the cleanliness of the area to be welded and the width of the welding seam. Judging whether welding operation can be performed or not according to the cleanliness, and determining the diameter of the laser beam according to the width of the welding line when the area to be welded is qualified.
S200: when the diameter of the laser beam is determined and the welding operation is judged to be possible, the laser is moved to the initial position of the area to be welded, depth data of the area to be welded are obtained based on ultrasonic waves, and the running power and the pulse frequency of the laser beam are determined according to the depth data.
S300: and collecting the material property of the area to be welded, and judging whether to start the gas protection device according to the material property. When it is determined that the area to be welded belongs to an oxidizable material, a gas protection device is turned on and a gas supply rate is determined.
S400: after determining whether to start the gas protection device, starting the laser to perform laser welding on the area to be welded, acquiring thermal imaging data of the area to be welded based on the thermal infrared imager in the welding process, and judging whether the inside of the area to be welded is welded in a melting mode according to the thermal imaging data. When the interior of the area to be welded is judged to be not welded in a melting mode, the pulse frequency of the laser beam is adjusted, and the operation is continued at the adjusted pulse frequency.
S500: and collecting the image data after the primary welding is finished, analyzing the image data after the primary welding is finished, and judging whether the welding result is qualified or not. And when the welding result is judged to be unqualified, performing secondary welding on the area after the primary welding is finished, acquiring the area of an unsuccessful welding area when performing secondary welding, and correcting the running power of the laser beam according to the area occupation ratio of the unsuccessful welding area.
Specifically, in S100, real-time image data of the welding area is acquired by using an image acquisition device such as a camera, and the image data is analyzed by an image processing algorithm, so as to extract information such as cleanliness and weld width of the area to be welded. The key characteristics of the welding area are obtained through visual information, and a basis is provided for adjustment of subsequent welding parameters. And S200, acquiring depth data of the area to be welded through equipment such as an ultrasonic sensor. The propagation speed of ultrasonic waves in a material is related to the density and the property of the material, and by analyzing the propagation time of ultrasonic waves in a region to be welded, depth information of the region to be welded can be deduced. This step is to determine the focal position and depth of weld at the time of laser welding, thereby adjusting the operating power and pulse frequency of the laser beam. And S300, judging whether the gas protection device needs to be started or not according to the material properties of the area to be welded. For readily oxidizable materials, it is determined whether an inert gas shield is required to be provided during the welding process to prevent oxidation by determining whether the material properties have readily oxidizable characteristics. And S400, after the welding is started, controlling the laser to move along the welding seam at a uniform speed, acquiring thermal imaging data of a region to be welded by using a thermal infrared imager when the welding is performed, and monitoring the temperature distribution condition in the welding process in real time. By analyzing the thermal imaging data, it can be determined whether the weld zone has reached the melting temperature, thereby evaluating the weld quality. In S500, whether the secondary welding is performed is judged according to the image data after the primary welding, and the welding condition is adaptively adjusted according to the actual situation during the secondary welding.
It can be appreciated that by collecting and analyzing the key information of the welding area in real time, the welding parameters can be automatically adjusted, so that the stability, efficiency and consistency of welding are improved, and the technical requirements of operators and the degree of human intervention are reduced.
In some embodiments of the present application, determining whether a welding operation is possible according to cleanliness, and determining a diameter of a laser beam according to a width of a weld when determining that a region to be welded is acceptable, includes: and comparing the cleanliness J with a preset standard cleanliness J0, and judging whether the welding operation can be performed on the area to be welded according to the comparison result.
Specifically, when J > J0, the welding operation can be performed by judging that the area to be welded is qualified. When J is less than or equal to J0, judging that dirt, impurities or residues exist in the area to be welded, and judging that the cleanliness is unqualified and the welding operation cannot be performed. When the area to be welded is qualified, the weld width K is respectively compared with a first preset weld width K1 and a second preset weld width K2, K1 is smaller than K2, and the diameter of the laser beam is determined according to the comparison result.
Specifically, when K.ltoreq.K1, the diameter of the laser beam is determined as a first preset diameter D1. When K1 is less than K and less than or equal to K2, determining the diameter of the laser beam as a second preset diameter D2. When K2 < K, the diameter of the laser beam is determined to be a third preset diameter D3. Wherein, 0 < D1 < D2 < D3.
It will be appreciated that a camera or other image acquisition device is used to capture or scan the surface to be inspected and obtain a digital image of the surface. Preprocessing the acquired image, including removing noise in the image, smoothing, enhancing contrast, and the like, to improve accuracy of cleanliness analysis. Features in the image, such as color, texture, brightness, etc., are extracted by image processing techniques to reflect the cleanliness of the surface. And analyzing and evaluating the cleanliness of the surface according to the extracted characteristics. And judging whether the surface meets the welding requirement according to the evaluation result of the cleanliness. If the cleanliness reaches the preset standard, the surface is considered to be subjected to welding operation; otherwise, a cleaning process or other pretreatment operation is required. The width of the weld is an important parameter in welding. If the diameter of the laser beam is similar to or slightly larger than the width of the welding seam, the laser beam can be ensured to completely cover the welding seam area, so that the welding process is more uniform and stable. Conversely, if the laser beam is too large, the energy may be excessively dispersed during welding, which affects the welding quality; if too small, the weld may not be completely covered, resulting in incomplete or unstable welding. The different beam diameters are set according to the width of the weld so as to fully cover the weld area during welding and to control the energy density of the laser beam, thereby achieving the best welding effect.
In some embodiments of the application, determining the operating power and pulse frequency of the laser beam from the depth data comprises: and respectively comparing the depth data H with a first preset depth H1 and a second preset depth H2 which are preset, wherein H1 is smaller than H2, and determining the running power and the pulse frequency of the laser beam according to the comparison result.
Specifically, when H is less than or equal to H1, determining the operation power of the laser beam as a first preset operation power P1, and determining the pulse frequency of the laser beam as a third preset pulse frequency M3. When H1 is more than H and less than or equal to H2, determining the operation power of the laser beam as second preset operation power P2, and determining the pulse frequency of the laser beam as second preset pulse frequency M2. When H2 is less than H, determining the operation power of the laser beam as a third preset operation power P3, and determining the pulse frequency of the laser beam as a first preset pulse frequency M1. Wherein, P1 is more than 0 and P2 is more than 3, M1 is more than 0 and M2 is more than 3.
It will be appreciated that the depth of the weld directly affects the energy required during the welding process. A shallower weld may require less energy to fully melt the weld area, while a deeper weld requires more energy to fully melt the weld area. The pulse frequency refers to the number of pulses emitted by the laser per unit time, while the energy of the pulses is typically fixed. When the pulse frequency is higher, the energy of the laser is transferred more frequently to the weld area, resulting in an increase in the local heat input. This accelerates the melting and thermal diffusion of the material, thereby melting deeper welds. Thus, adjusting the operating power and pulse frequency according to the depth of the weld ensures that proper energy delivery is provided under different depths of weld to meet weld quality requirements.
In some embodiments of the present application, determining whether to turn on the gas protection device based on the material property includes: and acquiring the material properties of the area to be welded according to the image data of the area to be welded. When the area to be welded belongs to the easily oxidized material, the gas protection device is started, and the gas supply rate is determined according to the depth data H. When the area to be welded belongs to a material which is not easy to oxidize, the gas protection device is not started.
It will be appreciated that by analyzing and processing the extracted features, a model or classifier is created that relates to the properties of the material to be welded. And judging and classifying the material properties of the area to be welded according to the analyzed characteristics and the established model. For example, whether a material is easily oxidized, is a metal, is a plastic, or the like is determined. The gas protection device is turned on when the material is an easily oxidizable material such as iron, steel, magnesium alloy, aluminum alloy, and titanium alloy, and is not turned on when the material is a non-easily oxidizable material such as stainless steel, copper, and alloy steel. The opening and closing of the gas protection device are intelligently controlled according to the material properties of the area to be welded, and the gas supply rate is adjusted according to the welding depth. This helps to improve the welding quality and stability, and simultaneously reduces the occurrence of defects such as oxidation and the like, and improves the reliability and consistency of welding.
In some embodiments of the application, when it is determined to turn on the gas protection device and determine the gas supply rate from the depth data H, it includes: when H is less than or equal to H1, determining the gas supply rate of the gas protection device as a first preset gas supply rate V1. When H1 is more than H and less than or equal to H2, determining the gas supply rate of the gas protection device as a second preset gas supply rate V2. When H2 < H, determining the gas supply rate of the gas protection device as a third preset gas supply rate V3. Wherein, V1 is more than 0 and V2 is more than 0 and V3.
It will be appreciated that when the depth of weld is small, the need for gas shielding is relatively small and a low gas supply rate may be employed to avoid wasting resources due to excessive gas flow. As the depth of weld increases, the weld area requires more gas shielding to ensure stability and quality during the welding process. Thus, as depth increases, a higher gas supply rate is selected to provide adequate protection. By adjusting the gas supply rate according to the welding depth, stability and quality during welding can be effectively improved. And different gas supply rates are adopted for different depth ranges, so that the fine control of the welding process can be realized, and the welding efficiency and the quality of finished products are improved.
In some embodiments of the present application, acquiring thermal imaging data of a region to be welded based on a thermal infrared imager during welding, and determining whether the interior of the region to be welded is fusion welded according to the thermal imaging data includes: and obtaining the melting depth R of the to-be-welded area according to the thermal imaging data, comparing the melting depth R with the depth data H, and judging whether the inside of the to-be-welded area is melted and welded according to the comparison result.
Specifically, when R < H, it is determined that the interior of the region to be welded is not welded by melting, and a depth difference Δh between the depth data H and the melting depth R is obtained, Δh=h-R, and the pulse frequency of the laser beam is adjusted according to the depth difference Δh, and the operation is continued at the adjusted pulse frequency. When R is more than or equal to H, the internal fusion welding of the area to be welded is judged, and the pulse frequency of the laser beam is not adjusted.
It will be appreciated that the thermal imaging data can reflect the temperature profile of the weld zone so that it can be indirectly understood whether the weld zone has melted. By comparing the melting depth R with the depth data H, it can be determined whether the interior of the welding region has been completely melted. If the depth of fusion is less than the depth data, it is indicated that the interior of the weld zone is not completely fused. According to the melting condition, the pulse frequency of the laser beam is adjusted, so that the problem in the welding process can be corrected in time, and the welding quality is ensured. Through the collection and analysis of thermal imaging data, the condition of a welding area in the welding process can be monitored in real time, and the problems in the welding process can be found and corrected in time. By adjusting the pulse frequency of the laser beam, the inside of the welding area can be ensured to be completely melted, thereby improving the welding quality and stability. Effectively reducing the possibility of welding defects in the welding process
In some embodiments of the present application, when the i-th preset pulse frequency Mi is selected as the pulse frequency of the laser beam and it is determined to adjust the pulse frequency Mi of the laser beam, i=1, 2,3, including: and respectively comparing the depth difference delta H with a first preset depth difference delta H1 and a second preset depth difference delta H2, wherein delta H1 is smaller than delta H2, and selecting an adjustment coefficient according to the comparison result to adjust the pulse frequency Mi of the laser beam so as to obtain the adjusted pulse frequency.
Specifically, when Δh is less than or equal to Δh1, a first preset adjustment coefficient A1 is selected to adjust the pulse frequency Mi of the laser beam, and the adjusted pulse frequency Mi is obtained. When Δh1 is smaller than Δh2 and is smaller than or equal to Δh2, a second preset adjustment coefficient A2 is selected to adjust the pulse frequency Mi of the laser beam, and adjusted pulse frequency M i ×a2 is obtained. When Δh2 is smaller than Δh, a third preset adjustment coefficient A3 is selected to adjust the pulse frequency Mi of the laser beam, and the adjusted pulse frequency mi×a3 is obtained. Wherein A3 is more than 0 and A2 is more than 0 and A1 is more than 1.
It will be appreciated that the depth difference Δh reflects the condition inside the weld zone and that different measures need to be taken to adjust the pulse frequency of the laser beam for different magnitudes of Δh. The pulse frequency can be flexibly adjusted by selecting different adjustment coefficients, welding parameters are optimized according to actual conditions, and stability and consistency of welding quality are further ensured. By selecting different adjustment coefficients according to the depth difference value delta H, the adjustment can be performed in time according to the internal conditions of the area in the welding process, so that the problems in the welding process are avoided. The pulse frequency after adjustment can better adapt to the change of a welding area, so that the stability and the quality of welding are improved, the incidence rate of welding defects is reduced, and the success rate and the efficiency of welding are improved.
In some embodiments of the present application, collecting image data after one welding is completed, analyzing the image data after one welding is completed, and determining whether the welding result is qualified, includes: judging whether cracking exists on the welding surface after one-time welding according to the image data after one-time welding.
Specifically, when the welding surface is cracked after the primary welding is completed, the welding result is judged to be unqualified, and secondary welding is required. And when no crack exists on the welding surface after one-time welding is finished, judging that the welding result is qualified.
In some embodiments of the present application, when it is determined that the welding result is not acceptable and a secondary welding is required, the method includes: and acquiring a cracking area Y, and acquiring a cracking area occupation ratio Z according to the cracking area Y, wherein Z=Y/Y0, and Y0 represents the area of the area to be welded. Comparing the area occupied ratio Z with a first preset area occupied ratio Z1 and a second preset area occupied ratio Z2 which are preset respectively, wherein Z1 is smaller than Z2, and determining a correction coefficient according to the comparison result to correct the running power Pn of the laser beam, wherein n=1, 2 and 3.
Specifically, when Z is less than or equal to Z1, a first preset correction coefficient B1 is selected to correct the operating power Pn of the laser beam, and corrected operating power pn×b1 is obtained. When Z1 is less than Z and less than or equal to Z2, a second preset correction coefficient B2 is selected to correct the operating power Pn of the laser beam, and the corrected operating power Pn is obtained. When Z2 is less than Z, a third preset correction coefficient B3 is selected to correct the operation power Pn of the laser beam, and the corrected operation power Pn is obtained. Wherein, B1 is more than 0 and B2 is more than 0 and B3 is more than 1.
It is understood that cracking, including cracks and pinholes, is a common problem in welding that can severely impact weld quality and strength. Through analysis and analysis of image data, whether the welding surface has cracks or not can be accurately detected, and corresponding processing can be timely carried out. For welded surfaces where cracks exist, a secondary weld repair is required to ensure the integrity and quality of the weld. By judging whether the welding surface is cracked or not, welding defects can be found in time, and unqualified welding quality caused by cracking is avoided. For the situation that the welding surface is cracked, a secondary welding repair measure is adopted, automatic welding can be carried out according to image data after primary welding is completed when secondary welding is carried out, manual welding can also be carried out, an operator wears a high-light-resistance electric welding laser mask when manual welding is carried out, a liquid crystal inductance screen is adopted as a mask surface screen 100 for high-light-resistance electric welding laser, the screen brightness can be adjusted according to current change, the screen is divided into 3-13 grades, a plurality of buttons are defined, and various brightness modes are adopted according to different requirements and working contents. The surface screen 100 is divided into 3 layers, the outer layer adopts transparent materials for absorbing ultraviolet and infrared and other harmful light, the inner layer adopts an inductance dimming screen, the middle layer adopts capillary copper pipe grid heat absorption layer medium as water, the copper pipe is hollow, and water flows through the middle. In the case of harmful light and harmful heat energy, the wearer's residence time may be increased, or welding may be performed for a long period of time. Meanwhile, the anti-strong light electric welding laser mask is provided with the earcaps 300, prevents noise, and is suitable for occasions with strong light radiation, ultraviolet rays, infrared rays and serious visible light radiation. An intercom system 400 and a video system 200 are arranged to realize remote assistance. And can also add high-pressure fan, filter dust and poison gas through active carbon and melt-blown cloth, close the face guard and just can have fresh air, add recording system, recording system can gather and store welding data with video system 200. Welding defects can be repaired in time through secondary welding, and welding quality and strength are improved. By adjusting the laser operating power, the heat input during the welding process can be controlled, thereby controlling the depth and temperature of the weld. In repairing welding defects, it is necessary to ensure that the welding conditions match the defective areas to avoid over-welding or under-welding.
In the embodiment, the technical means of image data analysis, depth data acquisition by ultrasonic waves, thermal imaging data acquisition by a thermal infrared imager and the like are utilized, so that the problems of fixed parameter setting, lack of intelligent adjustment and feedback mechanisms and large dependence on technicians existing in the traditional laser welding technology are solved. The welding process is more intelligent and self-adaptive by collecting image data and material properties of a welding area, judging the welding feasibility based on factors such as cleanliness and weld width, and starting a gas protection device according to material characteristics. And in the welding process, the internal condition of the area to be welded is monitored in real time, whether the welding area is welded in a melting way or not is judged by acquiring thermal imaging data through the thermal infrared imager, and the parameters of the laser beam are dynamically adjusted when the welding is judged to be unqualified, so that the welding quality is ensured. In addition, the secondary welding function is further provided, unqualified welding areas can be corrected and welded after primary welding is finished, and welding efficiency and consistency are improved. Is beneficial to improving the welding quality, efficiency and stability.
In another preferred mode based on the above embodiment, referring to fig. 2, there is provided a laser beam welding system for applying the above laser beam welding method, including:
The acquisition unit is configured to acquire image data of a welding area, and analyzes the image data to acquire the cleanliness and the weld width of the area to be welded; judging whether welding operation can be performed or not according to the cleanliness, and determining the diameter of the laser beam according to the width of the welding line when the area to be welded is determined to be qualified;
The processing unit is configured to move the laser to the initial position of the area to be welded and acquire depth data of the area to be welded based on ultrasonic waves when the diameter of the laser beam is determined and welding operation can be carried out, and the operation power and the pulse frequency of the laser beam are determined according to the depth data;
The judging unit is configured to not collect the material attribute of the area to be welded and judge whether to open the gas protection device according to the material attribute; when the area to be welded is judged to belong to the easily-oxidizable material, starting a gas protection device and determining a gas supply rate;
The adjusting unit is configured to start the laser to carry out laser welding on the area to be welded after determining whether the gas protection device is started, collect thermal imaging data of the area to be welded based on the thermal infrared imager in the welding process, and judge whether the interior of the area to be welded is welded in a melting way according to the thermal imaging data; when the interior of the area to be welded is judged to be not welded in a melting way, the pulse frequency of the laser beam is adjusted, and the operation is continued at the adjusted pulse frequency;
The correction unit is configured to acquire image data after one-time welding, analyze the image data after one-time welding and judge whether a welding result is qualified or not; and when the welding result is judged to be unqualified, performing secondary welding on the area after the primary welding is finished, acquiring the area of an unsuccessful welding area when performing secondary welding, and correcting the running power of the laser beam according to the area occupation ratio of the unsuccessful welding area.
It can be understood that the problems of fixed parameter setting, lack of intelligent adjustment and feedback mechanisms and large dependence on technicians existing in the traditional laser welding technology are solved by the technical means of image data analysis, depth data acquisition by ultrasonic waves, thermal imaging data acquisition by a thermal infrared imager and the like. The welding process is more intelligent and self-adaptive by collecting image data and material properties of a welding area, judging the welding feasibility based on factors such as cleanliness and weld width, and starting a gas protection device according to material characteristics. And in the welding process, the internal condition of the area to be welded is monitored in real time, whether the welding area is welded in a melting way or not is judged by acquiring thermal imaging data through the thermal infrared imager, and the parameters of the laser beam are dynamically adjusted when the welding is judged to be unqualified, so that the welding quality is ensured. In addition, the secondary welding function is further provided, unqualified welding areas can be corrected and welded after primary welding is finished, and welding efficiency and consistency are improved. Is beneficial to improving the welding quality, efficiency and stability.
It will be appreciated by those skilled in the art that embodiments of the present application may be provided as a method, system, or computer program product. Accordingly, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present application may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and the like) having computer-usable program code embodied therein.
The present application is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the application. It will be understood that each flowchart and/or block of the flowchart illustrations and/or block diagrams, and combinations of flowcharts and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
Finally, it should be noted that: the above embodiments are only for illustrating the technical aspects of the present invention and not for limiting the same, and although the present invention has been described in detail with reference to the above embodiments, it should be understood by those of ordinary skill in the art that: modifications and equivalents may be made to the specific embodiments of the invention without departing from the spirit and scope of the invention, which is intended to be covered by the claims.
Claims (10)
1. A laser beam welding method, comprising:
Collecting image data of a welding area, and analyzing the image data to obtain the cleanliness of the area to be welded and the width of a welding seam;
Judging whether welding operation can be performed or not according to the cleanliness, and determining the diameter of a laser beam according to the width of the welding line when the area to be welded is determined to be qualified;
When the diameter of the laser beam is determined and welding operation can be carried out, moving a laser to the initial position of the area to be welded, acquiring depth data of the area to be welded based on ultrasonic waves, and determining the running power and the pulse frequency of the laser beam according to the depth data;
collecting material properties of the area to be welded, and judging whether to start a gas protection device according to the material properties; when the area to be welded is judged to belong to the easily-oxidizable material, starting the gas protection device and determining a gas supply rate;
after determining whether to start the gas protection device, starting the laser to carry out laser welding on the to-be-welded area, acquiring thermal imaging data of the to-be-welded area based on a thermal infrared imager in the welding process, and judging whether the inside of the to-be-welded area is welded in a melting manner according to the thermal imaging data; when the interior of the area to be welded is judged to be not welded in a melting way, the pulse frequency of the laser beam is adjusted, and the operation is continued at the adjusted pulse frequency;
Collecting image data after one-time welding, analyzing the image data after one-time welding and judging whether a welding result is qualified or not; and when the welding result is judged to be unqualified, performing secondary welding on the area after the primary welding is finished, acquiring the area of an unsuccessful welding area when performing secondary welding, and correcting the running power of the laser beam according to the area occupation ratio of the unsuccessful welding area.
2. The laser beam welding method according to claim 1, wherein determining whether a welding operation is possible based on the cleanliness, and determining a diameter of a laser beam based on the weld width when determining that the area to be welded is acceptable, comprises:
Comparing the cleanliness J with a preset standard cleanliness J0, and judging whether the area to be welded can be subjected to welding operation or not according to a comparison result;
when J is more than J0, judging that the area to be welded is qualified and performing welding operation;
when J is less than or equal to J0, judging that dirt, impurities or residues exist in the area to be welded, wherein the cleanliness is unqualified, and the welding operation cannot be performed;
when the to-be-welded area is determined to be qualified, the welding seam width K is respectively compared with a first preset welding seam width K1 and a second preset welding seam width K2, K1 is smaller than K2, and the diameter of the laser beam is determined according to the comparison result;
When K is less than or equal to K1, determining the diameter of the laser beam as a first preset diameter D1;
when K1 is more than K and less than or equal to K2, determining the diameter of the laser beam as a second preset diameter D2;
when K2 is less than K, determining the diameter of the laser beam as a third preset diameter D3;
Wherein, 0 < D1 < D2 < D3.
3. The laser beam welding method according to claim 2, wherein determining the operating power and pulse frequency of the laser beam from the depth data comprises:
Comparing the depth data H with a first preset depth H1 and a second preset depth H2 which are preset respectively, wherein H1 is smaller than H2, and determining the running power and the pulse frequency of the laser beam according to the comparison result;
when H is less than or equal to H1, determining the operation power of the laser beam as a first preset operation power P1, and determining the pulse frequency of the laser beam as a third preset pulse frequency M3;
When H1 is more than H and less than or equal to H2, determining the running power of the laser beam as second preset running power P2, and determining the pulse frequency of the laser beam as second preset pulse frequency M2;
When H2 is less than H, determining the operation power of the laser beam as a third preset operation power P3, and determining the pulse frequency of the laser beam as a first preset pulse frequency M1;
Wherein, P1 is more than 0 and P2 is more than 3, M1 is more than 0 and M2 is more than 3.
4. The laser beam welding method according to claim 3, wherein determining whether to turn on the gas shielding device based on the material property comprises:
Acquiring the material properties of the region to be welded according to the image data of the region to be welded;
When the area to be welded belongs to an oxidizable material, starting the gas protection device and determining the gas supply rate according to the depth data H;
and when the area to be welded belongs to a material which is not easy to oxidize, the gas protection device is not started.
5. The laser beam welding method according to claim 4, characterized by, when it is determined to turn on the gas protection device and to determine the gas supply rate from the depth data H, comprising:
when H is less than or equal to H1, determining the gas supply rate of the gas protection device as a first preset gas supply rate V1;
When H1 is more than H and less than or equal to H2, determining the gas supply rate of the gas protection device to be a second preset gas supply rate V2;
when H2 is less than H, determining the gas supply rate of the gas protection device to be a third preset gas supply rate V3;
Wherein, V1 is more than 0 and V2 is more than 0 and V3.
6. The laser beam welding method according to claim 3, wherein the step of acquiring thermal imaging data of the region to be welded based on a thermal infrared imager during welding and judging whether the interior of the region to be welded is fusion welded based on the thermal imaging data comprises:
obtaining the melting depth R of the region to be welded according to the thermal imaging data, comparing the melting depth R with the depth data H, and judging whether the interior of the region to be welded is melted and welded according to a comparison result;
When R is less than H, judging that the interior of the area to be welded is not welded in a melting way, acquiring depth difference delta H between the depth data H and the melting depth R, wherein delta H=H-R, and adjusting the pulse frequency of the laser beam according to the depth difference delta H so as to continue to operate at the adjusted pulse frequency;
when R is more than or equal to H, the internal fusion welding of the area to be welded is judged, and the pulse frequency of the laser beam is not adjusted.
7. The laser beam welding method according to claim 6, wherein when an i-th preset pulse frequency Mi is selected as the pulse frequency of the laser beam and it is determined to adjust the pulse frequency Mi of the laser beam, i=1, 2,3, comprising:
comparing the depth difference delta H with a first preset depth difference delta H1 and a second preset depth difference delta H2, wherein delta H1 is smaller than delta H2, and selecting an adjustment coefficient according to the comparison result to adjust the pulse frequency Mi of the laser beam to obtain the adjusted pulse frequency;
When delta H is less than or equal to delta H1, selecting a first preset adjustment coefficient A1 to adjust the pulse frequency Mi of the laser beam, and obtaining the adjusted pulse frequency Mi;
when delta H1 is less than delta H and less than or equal to delta H2, selecting a second preset adjustment coefficient A2 to adjust the pulse frequency Mi of the laser beam, and obtaining the adjusted pulse frequency Mi;
when delta H2 is smaller than delta H, selecting a third preset adjustment coefficient A3 to adjust the pulse frequency Mi of the laser beam, and obtaining the adjusted pulse frequency Mi;
wherein A3 is more than 0 and A2 is more than 0 and A1 is more than 1.
8. The laser beam welding method according to claim 7, wherein collecting image data after one welding is completed, analyzing the image data after one welding is completed, and judging whether the welding result is qualified, comprises:
Judging whether cracking exists on the welding surface after the primary welding is finished according to the image data after the primary welding is finished;
When the welding surface is cracked after the primary welding is finished, judging that the welding result is unqualified, and performing secondary welding;
And when the welding surface is not cracked after one-time welding is finished, judging that the welding result is qualified.
9. The laser beam welding method according to claim 8, wherein when it is determined that the welding result is not acceptable and secondary welding is required, comprising:
Acquiring a cracking area Y, and acquiring a cracking area occupation ratio Z according to the cracking area Y, wherein Z=Y/Y0, and Y0 represents the area of the area to be welded; comparing the area occupation ratio Z with a first preset area occupation ratio Z1 and a second preset area occupation ratio Z2 which are preset respectively, wherein Z1 is smaller than Z2, and determining a correction coefficient according to the comparison result to correct the running power Pn of the laser beam, wherein n=1, 2 and 3;
When Z is less than or equal to Z1, a first preset correction coefficient B1 is selected to correct the operating power Pn of the laser beam, and corrected operating power Pn is obtained;
When Z1 is more than Z and less than or equal to Z2, selecting a second preset correction coefficient B2 to correct the operating power Pn of the laser beam, and obtaining corrected operating power Pn x B2;
When Z2 is less than Z, selecting a third preset correction coefficient B3 to correct the operation power Pn of the laser beam, and obtaining corrected operation power Pn x B3;
Wherein, B1 is more than 0 and B2 is more than 0 and B3 is more than 1.
10. A laser beam welding system for applying the laser beam welding method according to any one of claims 1-9, comprising:
The acquisition unit is configured to acquire image data of a welding area, and analyze the image data to acquire the cleanliness and the welding line width of the area to be welded; judging whether welding operation can be performed or not according to the cleanliness, and determining the diameter of a laser beam according to the width of the welding line when the area to be welded is determined to be qualified;
the processing unit is configured to move the laser to the initial position of the area to be welded and acquire depth data of the area to be welded based on ultrasonic waves when the diameter of the laser beam is determined and welding operation can be carried out, and the operation power and the pulse frequency of the laser beam are determined according to the depth data;
The judging unit is configured to judge whether to start the gas protection device according to the material attribute of the area to be welded, which is not acquired; when the area to be welded is judged to belong to the easily-oxidizable material, starting the gas protection device and determining a gas supply rate;
The adjusting unit is configured to start the laser to carry out laser welding on the area to be welded after determining whether the gas protection device is started, collect thermal imaging data of the area to be welded based on a thermal infrared imager in the welding process, and judge whether the interior of the area to be welded is welded in a melting mode according to the thermal imaging data; when the interior of the area to be welded is judged to be not welded in a melting way, the pulse frequency of the laser beam is adjusted, and the operation is continued at the adjusted pulse frequency;
The correction unit is configured to acquire image data after one-time welding, analyze the image data after one-time welding and judge whether a welding result is qualified or not; and when the welding result is judged to be unqualified, performing secondary welding on the area after the primary welding is finished, acquiring the area of an unsuccessful welding area when performing secondary welding, and correcting the running power of the laser beam according to the area occupation ratio of the unsuccessful welding area.
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