WO2022179626A1 - 焊接质量检测系统及超声波焊接设备、焊接质量检测方法 - Google Patents

焊接质量检测系统及超声波焊接设备、焊接质量检测方法 Download PDF

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Publication number
WO2022179626A1
WO2022179626A1 PCT/CN2022/078040 CN2022078040W WO2022179626A1 WO 2022179626 A1 WO2022179626 A1 WO 2022179626A1 CN 2022078040 W CN2022078040 W CN 2022078040W WO 2022179626 A1 WO2022179626 A1 WO 2022179626A1
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Prior art keywords
welding
friction force
longitudinal
reference value
control module
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PCT/CN2022/078040
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English (en)
French (fr)
Inventor
周俊雄
杜义贤
陈德
卢其辉
范鹏
Original Assignee
广东利元亨智能装备股份有限公司
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Priority to US17/774,108 priority Critical patent/US20230158610A1/en
Publication of WO2022179626A1 publication Critical patent/WO2022179626A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N19/00—Investigating materials by mechanical methods
    • 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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
    • G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes

Definitions

  • the present application relates to the technical field of ultrasonic welding, and in particular, to a welding quality detection system, ultrasonic welding equipment, and a welding quality detection method.
  • the ultrasonic metal welding machine is used to weld two or more workpieces, and the difference in the surface quality of the workpieces to be welded, such as surface finish, oil, dust, etc., will lead to changes in the shear force or friction during welding, among which , factors that affect friction include material selection (e.g. copper or aluminum composition, and its purity), surface coatings, grease between tabs or harnesses, additives and dirt, material storage environment and time, material surface damage, and Longitudinal welding pressure, thus affecting the welding quality (welding strength), such as virtual welding, insufficient tension and other problems.
  • material selection e.g. copper or aluminum composition, and its purity
  • surface coatings e.g. copper or aluminum composition, and its purity
  • surface coatings e.g. copper or aluminum composition, and its purity
  • surface coatings e.g. copper or aluminum composition, and its purity
  • surface coatings e.g. copper or aluminum composition, and its purity
  • grease between tabs or harnesses e.g. copper
  • the ultrasonic vibration is transmitted to the compressed metal sheet, and the tangential vibration cleans the oil and decomposes the oxide on the surface of the material, creating a clean contact between the multi-layer metal sheets.
  • the atoms on both sides of the contact surface are shared to form a connection.
  • most welding defects are difficult to identify before failure, and the cost caused by defects is high, so it is necessary to effectively detect the welding quality.
  • the purpose of this application is to solve at least one of the technical problems existing in the prior art.
  • the present application provides a welding quality detection system that can effectively detect the welding quality of the welding workpiece and discover welding defects in time.
  • the present application also provides an ultrasonic welding device equipped with the above-mentioned welding quality detection system.
  • the present application also provides a welding quality detection method of the welding quality detection system.
  • the welding quality detection system includes: a detection module for collecting the lateral friction force and longitudinal welding pressure of the welding workpiece; a control module, the control module is electrically connected with the detection module, and the The control module is used to receive and analyze and process the lateral frictional force signal and the longitudinal welding pressure signal of the detection module; a display module is electrically connected to the control module, and the display module is used to display the analysis result of the control module .
  • the above technical solution at least has the following beneficial effects: the lateral friction force and the longitudinal welding pressure of the welding workpiece are collected in real time by the detection module, and the signal of the detection module is received by the control module and the lateral friction force and the longitudinal welding pressure of the welding workpiece are analyzed and processed, In order to judge whether the welding workpiece is a good product, the analysis results are displayed on the display module and fed back to the operator in time. Therefore, the welding quality of the welding workpiece can be judged in time, the workpiece with welding defects can be found in advance, and the safety caused by defects can be avoided in the later stage. hidden dangers or cost waste.
  • the detection module is configured as a multi-dimensional force sensor, and the multi-dimensional force sensor is used to collect the transverse friction force and longitudinal welding pressure of the welding workpiece and convert them into analog voltage signals respectively, which can accurately detect multiple directions on the force value.
  • the display module is configured as a human-machine interface (HMI), a computer (PC) or an indicator light, which can visually display the analysis results.
  • HMI human-machine interface
  • PC computer
  • indicator light which can visually display the analysis results.
  • the ultrasonic welding equipment includes: a machine base, which is provided with a welding base; ; a driving member, which is connected with the welding member and drives the welding member to move in the up and down direction; in the welding quality detection system according to the embodiment of the first aspect, the detection module is installed on the welding base.
  • the ultrasonic welding equipment collects the transverse friction force and longitudinal welding pressure of the welding workpiece in real time through the detection module, and the control module receives the signal of the detection module and performs the transverse friction force and longitudinal welding pressure of the welding workpiece.
  • Analysis and processing to judge whether the welding workpiece is a good product and display the analysis results on the display module and feed back to the operator in time. Therefore, the welding quality of the welding workpiece can be judged in time, and the workpiece with welding defects can be found in advance, so as to avoid defects in the later stage. This may result in safety hazards or cost waste.
  • the welding quality detection system includes a detection module, a control module and a display module, and the detection module is used for collecting welding workpieces The lateral friction force and longitudinal welding pressure of the detection module; the control module is electrically connected with the detection module, and the control module is used to receive and analyze the lateral friction force signal and longitudinal welding pressure signal of the detection module; the display The module is electrically connected with the control module, the display module is used for displaying the analysis result of the control module, and the welding quality detection method includes the following steps: respectively obtaining the reference value ranges of the transverse friction force and the longitudinal welding pressure, and The reference value range is set in the control module; the lateral friction force and longitudinal welding pressure of the welding workpiece are collected in real time by the detection module and transmitted to the control module in the form of electrical signals; The friction force and the longitudinal welding pressure are respectively compared with the corresponding reference value ranges; the control module transmits the analysis
  • the above technical solution at least has the following beneficial effects: the lateral friction force and the longitudinal welding pressure of the welding workpiece are collected in real time by the detection module, and the signal of the detection module is received by the control module, and the lateral friction force and longitudinal welding pressure of the welding workpiece are respectively corresponding to the corresponding.
  • the benchmark value range is compared to judge whether the welding workpiece is a good product, and the analysis results are displayed on the display module and fed back to the operator in time. Therefore, the welding quality of the welding workpiece can be judged in time, and the workpiece with welding defects can be found in advance to avoid In the later stage, there will be safety hazards or cost waste due to defects.
  • the process of obtaining the reference value ranges of the transverse friction force and the longitudinal welding pressure respectively includes the following steps: collecting the transverse friction force and longitudinal welding pressure of the welding workpieces of small batches of samples; welding the workpieces for each sample Carry out quality analysis respectively; record the transverse friction force and longitudinal welding pressure of the sample welding workpiece as good products; calculate the average value ⁇ 1 and deviation value D1 of transverse friction force, and calculate the average value ⁇ 2 and deviation value D2 of longitudinal welding pressure; according to the average value ⁇ 1 And the deviation value D1 to determine the reference value range of the lateral friction force, according to the average value ⁇ 2 and the deviation value D2 to determine the reference value range of the longitudinal welding pressure, in order to obtain an accurate reference value range.
  • the quality analysis process includes tensile test and microstructure analysis, which can accurately judge the welding quality of the sample welding workpiece.
  • the process of obtaining the reference value ranges of the transverse friction force and the longitudinal welding pressure respectively includes the following steps: collecting the transverse friction force and longitudinal welding pressure of the welding workpieces of small batches of samples; adopting a normal distribution statistical method The transverse friction force and longitudinal welding pressure of the sample welding workpiece were sorted out respectively; the numerical range within three standard deviations from the average value of transverse friction force was determined as the reference value range of transverse friction force, The numerical range within the standard deviation is determined as the reference value range of the longitudinal welding pressure, and another type of reference value range can be obtained to further improve the accuracy of welding quality detection.
  • the use of a normal distribution statistical method to sort out the transverse friction force and longitudinal welding pressure of the sample welding workpiece respectively includes counting the number of transverse friction force values and longitudinal welding pressure values and plotting the normal distributions respectively.
  • Figure calculate the mean and standard deviation of the transverse friction force and calculate the mean and standard deviation of the longitudinal welding pressure.
  • the control module comparing the lateral friction force and the longitudinal welding pressure with the corresponding reference value ranges respectively includes the following steps: comparing the lateral friction force collected in real time with the reference value range of the lateral friction force, Compare the longitudinal welding pressure collected in real time with the reference value range of the longitudinal welding pressure; if the lateral friction force exceeds the reference value range of the transverse friction force and/or the longitudinal welding pressure exceeds the reference value range of the longitudinal welding pressure, it will be judged as an unqualified product. If the friction force is within the range of the reference value of the lateral friction force and the longitudinal welding pressure is within the range of the reference value of the longitudinal welding pressure, it is judged as a good product.
  • FIG. 1 is a system architecture diagram of a welding quality detection system in an embodiment of the application
  • FIG. 2 is a schematic structural diagram of an ultrasonic welding device in an embodiment of the application.
  • FIG. 3 is a process step diagram of the welding quality detection method in the first embodiment of the application.
  • Fig. 4 is a specific process step diagram of step S100 in Fig. 3;
  • Fig. 5 is a specific process step diagram of step S300 in Fig. 3;
  • FIG. 6 is a specific process step diagram of step S100 in the welding quality detection method in the second embodiment of the application.
  • FIG. 7 is a system architecture diagram of a control module in an embodiment of the present application.
  • Welding quality detection system 110 detection module 111, control module 112, memory 1121, processor 1122, display module 113;
  • orientation or positional relationship indicated in relation to orientation description is based on the orientation or positional relationship shown in the accompanying drawings, only For the convenience of describing the present application and simplifying the description, it is not indicated or implied that the referred device or element must have a particular orientation, be constructed and operate in a particular orientation, and therefore should not be construed as a limitation of the present application.
  • the meaning of several is one or more, the meaning of multiple is two or more, greater than, less than, exceeding, etc., are understood as not including this number, and above, below, within, etc., are understood as including this number. If it is described that the first and the second are only for the purpose of distinguishing technical features, it cannot be understood as indicating or implying relative importance, or indicating the number of the indicated technical features or the order of the indicated technical features. relation.
  • a welding quality detection system 110 is provided for some embodiments of the first aspect of the application, which is installed on the ultrasonic welding equipment 100.
  • the welding quality detection system 110 includes a detection module 111, a control module 112 and a display module 113, and controls the
  • the module 112 is electrically connected to the detection module 111
  • the display module 113 is electrically connected to the control module 112 .
  • the detection module 111 is configured as a multi-dimensional force sensor, and the multi-dimensional force sensor can detect force values in multiple directions.
  • the ultrasonic vibration is a lateral displacement, and an alternating shearing force is generated in the horizontal direction.
  • the shearing force is equal to the frictional force between the two welding workpieces, so it is a lateral frictional force.
  • the downward pressure of the welding workpiece in the vertical direction is the longitudinal welding pressure; in general, the multi-dimensional force sensor collects the lateral friction force and the longitudinal welding pressure and converts them into analog voltage signals and amplifies them for transmission to the control module 112.
  • the control module 112 receives the analog signals of the lateral friction force and longitudinal welding pressure of the detection module 111, it analyzes and processes them, and the control module 112 is a programmable controller (PLC) or single-chip microcomputer, etc., obtain the corresponding force value through program conversion processing, so as to compare with the reference value range and obtain the analysis result, that is, whether the welding workpiece is a good product, and transmit the analysis result to the display module 113, and the display module 113 It is a terminal device such as a human-machine interface (HMI) or a computer (PC), which can intuitively display the analysis results in the form of text, so as to intuitively feed back the analysis results to the operator; of course, it can be understood that the display module 113 can also Display the horizontal friction force value and longitudinal welding pressure value of the welding workpiece, as well as the reference value range, to further improve the intuitiveness of the analysis results; the display module 113 can also
  • the lateral friction force and longitudinal welding pressure of the welding workpiece are collected in real time by the detection module 111, and the control module 112 receives the signal of the detection module 111 and performs the measurement on the lateral friction force and longitudinal welding pressure of the welding workpiece.
  • Analysis and processing to judge whether the welding workpiece is a good product, and display the analysis results on the display module 113, and feed back to the operator in time. Therefore, the welding quality of the welding workpiece can be judged in time, and the workpiece with welding defects can be found in advance, so as to avoid later problems. Defects cause safety hazards or cost waste.
  • the ultrasonic welding equipment 100 includes a base 120, a welding member 130, a driving member 140 and the above-mentioned welding quality detection system 110.
  • the base 120 is provided with a welding base 121, and the welding base 121 is used to position two welding workpieces, the welding member 130 is slidably connected to the machine base 120 in the up-down direction, and the welding member 130 is arranged as a triplet, including the transducer 131, the amplitude modulator 132 and the welding head 133 connected in sequence along the horizontal direction,
  • the welding head 133 is located directly above the welding base 121 , the driving member 140 is fixedly installed on the machine base 120 , the driving member 140 is an air cylinder or other driving cylinder, and the driving shaft of the driving member 140 is connected with the welding member 130 and drives the welding member 130 Moving in the up and down direction to realize the welding of the workpiece, the detection module 111 (ie the multi-dimensional force sensor) in the welding quality detection system 110 is installed on the welding base 120 .
  • an alternating shear force is generated in the horizontal direction during the ultrasonic vibration process, and the shear force is equal to the friction force between the two workpieces, that is, the transverse friction force , the above two forces are affected by factors such as materials and the coating on the surface of the workpiece.
  • the stability and quality of welding can be judged by the above two forces; during the welding process, the detection module 111 (multi-dimensional force sensor) collects the transverse direction of the welding workpiece in real time.
  • the friction force and longitudinal welding pressure are respectively converted into analog voltage signals and transmitted to the control module 112.
  • control module 112 After the control module 112 receives the analog voltage signal from the detection module 111, it analyzes and processes the signals, and timely judges whether the welding workpiece is a good product, and The analysis result is transmitted to the display module 113, and the analysis result is fed back to the operator intuitively. Therefore, the welding quality of the welding workpiece can be judged in time, and the workpiece with welding defects can be found in advance, so as to avoid potential safety hazards or cost caused by defects in the later stage. waste.
  • the welding quality detection method of the third aspect of the application is applied to the ultrasonic welding equipment 100 of FIG. 2 and the welding quality detection system 110 of FIG. 1 .
  • the welding quality detection method in this embodiment can be
  • the detection module 111 , the control module 112 and the display module 113 in the welding quality detection system 110 in some embodiments of the present application are implemented to detect the welding quality of the welding workpiece in real time, determine whether the welding workpiece is a good product, and find the workpiece with welding defects in advance . It should be noted that the following descriptions are only exemplary descriptions, rather than specific limitations to the application.
  • FIG. 3 it is the first embodiment of the welding quality inspection method in this application, which includes the following steps:
  • Step S100 respectively acquiring the reference value ranges of the lateral friction force and the longitudinal welding pressure, and setting the reference value ranges in the control module 112;
  • Step S200 Collect the lateral friction force and longitudinal welding pressure of the welding workpiece in real time through the detection module 111 and transmit them to the control module 112 in the form of electrical signals respectively;
  • Step S300 the control module 112 compares the transverse friction force and the longitudinal welding pressure with the corresponding reference value ranges respectively;
  • Step S400 the control module 112 transmits the analysis result to the display module 113 and the display module 113 displays the analysis result.
  • the range of the reference value of the lateral friction force and the range of the reference value of the longitudinal welding pressure obtained in advance are set in the control module 112, and the detection module 111 (ie, the multi-dimensional force sensor) collects the information of the welding workpiece during the welding process.
  • the lateral friction force and the longitudinal welding pressure are converted into analog voltage signals, and the control module 112 receives the analog voltage signals transmitted by the detection module 111 and converts them into corresponding force values through the program, so that they can be compared with the preset reference value range.
  • step S100 the process of obtaining the reference value ranges of the transverse friction force and the longitudinal welding pressure respectively includes the following steps:
  • Step S110 collect the transverse friction force and longitudinal welding pressure of the welding workpiece in small batches
  • Step S120 Perform quality analysis on each sample welding workpiece
  • Step S130 record the transverse friction force and longitudinal welding pressure of the sample welding workpiece as a good product
  • Step S140 Calculate the average value ⁇ 1 and the deviation value D1 of the transverse friction force, and calculate the average value ⁇ 2 and the deviation value D2 of the longitudinal welding pressure;
  • Step S150 Determine the reference value range of the lateral friction force according to the average value ⁇ 1 and the deviation value D1, and determine the reference value range of the longitudinal welding pressure according to the average value ⁇ 2 and the deviation value D2.
  • the reference value range is calculated by welding workpiece data for good samples, and the upper and lower limit values of the reference value range are determined, so that the welding quality of the welding workpiece can be accurately judged, and the upper and lower limit comparison method can quickly judge the welding workpiece. Whether the welding parameters meet the requirements.
  • the average value ⁇ 1 is obtained after summing the transverse friction forces of the sample welded workpieces as good products, the difference between the maximum transverse friction force and the average value ⁇ 1 and the minimum transverse friction force and the average value in the welded workpieces with good products
  • the difference between ⁇ 1 take the smaller one as the deviation value D1
  • the reference value range of the lateral friction force is ( ⁇ 1-D1) ⁇ ( ⁇ 1+D1) (including the endpoint value), that is, the reference value of the lateral friction force
  • the upper limit of the range is ( ⁇ 1+D1), and the lower limit is ( ⁇ 1-D1).
  • the upper limit and the lower limit can be set in the control module 112; of course, it can be understood that according to customer requirements or On-site process requirements, double deviation 2D1 or triple deviation 3D1 or other multiple deviation ranges can be selected as the reference value range of lateral friction force, that is, the reference value range of lateral friction force is ( ⁇ 1-2D1) ⁇ ( ⁇ 1+2D1) (including the endpoint value), the upper limit of the reference value range of the corresponding lateral friction force is ( ⁇ 1+2D1), the lower limit is ( ⁇ 1-2D1), or the reference value range of the lateral friction force is ( ⁇ 1-3D1) ⁇ ( ⁇ 1+3D1) (including the endpoint value), the upper limit of the reference value range corresponding to the lateral friction force is ( ⁇ 1+3D1), the lower limit is ( ⁇ 1-3D1), or others; the same way to obtain the longitudinal welding pressure
  • the range of the reference value is ( ⁇ 2-D2) ⁇ ( ⁇ 2+D2) (including the endpoint value), that is, the upper limit of the reference value range of
  • the quality analysis of each sample welded workpiece includes tensile test and microstructure analysis, wherein, the tensile test is to pull two welded workpieces by a welding tensile testing machine to check the welding workpiece. Fracture toughness, that is, whether the tensile force value that the two workpieces can withstand after welding meets the limit value requirements specified by the industry standard or the customer; the microstructure analysis is to observe the structure of the weld or weld through a professional precision instrument, and measure the weld.
  • the parameters of the weld such as residual area, etc.
  • the parameters of the weld to judge whether the parameters of the weld or the weld meet the industry standards or customer requirements; if the tensile force value and the parameters of the weld or welding meet the requirements, the sample welded workpiece is judged as a good product , record the lateral friction force and longitudinal friction force of the good product, otherwise the sample is judged as a non-conforming product.
  • step S300 the control module 112 compares the transverse friction force and the longitudinal welding pressure with the corresponding reference value ranges, including the following steps:
  • Step S310 Compare the lateral friction force collected in real time with the reference value range of the lateral friction force, and compare the longitudinal welding pressure collected in real time with the reference value range of the longitudinal welding pressure;
  • Step S320 If the lateral friction force exceeds the range of the reference value of the lateral friction force and/or the longitudinal welding pressure exceeds the range of the reference value of the longitudinal welding pressure, it is determined as an unqualified product; if the lateral friction force is within the range of the reference value of the lateral friction force and the longitudinal welding pressure Within the range of the longitudinal welding pressure reference value, it is judged as a good product.
  • the detection module 111 collects the lateral friction force and longitudinal welding pressure of the welding workpiece in real time and converts them into analog voltage signals.
  • the recognized transverse friction force and longitudinal welding pressure value compare the transverse friction force value with the reference value range of transverse friction force, that is, compare the transverse friction force value with the upper and lower limit values of the reference value range of transverse friction force , compare the longitudinal welding pressure value with the reference value range of the longitudinal welding pressure, that is, compare the longitudinal welding pressure value with the upper limit and lower limit of the reference value range of the longitudinal welding pressure, in the following two conditions: 1) Transverse The friction force value is within the reference value range of the transverse friction force, including the case where it is exactly the end value of the reference value range of the transverse friction force; 2) The value of the longitudinal welding pressure is within the reference value range of the longitudinal welding pressure, including the case where the longitudinal welding pressure is exactly the end value of the reference value range.
  • the welding quality of the welding workpiece can be quickly judged, and the analysis results can be displayed on the display module 113 intuitively, and the feedback can be timely fed back to the operator to judge the welding quality of the welding workpiece in time, and discover the existence of welding in advance.
  • Defective workpieces can avoid potential safety hazards or cost waste due to defects in the later stage.
  • step S100 the process of obtaining the reference value ranges of the lateral friction force and the longitudinal welding pressure in step S100 is different from that of the first embodiment, the rest are the same as those of the first embodiment.
  • the embodiments are the same, and are not repeated here.
  • step S100 the process of obtaining the reference value ranges of the transverse friction force and the longitudinal welding pressure respectively includes the following steps:
  • S160 Collect the transverse friction force and longitudinal welding pressure of the welding workpiece in small batches
  • S170 Use the normal distribution statistical method to sort out the transverse friction force and longitudinal welding pressure of the sample welding workpiece respectively;
  • S180 Determine the numerical range within three standard deviations from the average value of the transverse friction force as the reference value range of the transverse friction force, and determine the numerical range within three standard deviations from the average value of the longitudinal welding pressure as the reference value of the longitudinal welding pressure scope.
  • the numerical values of the lateral friction force of all the samples are classified and counted, and the numerical value of the lateral friction force is the abscissa, and the number of samples corresponding to the numerical value is the ordinate, and the data points of all the samples are depicted in the coordinate system.
  • the lateral friction force value conforms to the normal distribution, so that the normal distribution diagram of the lateral friction force can be obtained, and the average value ⁇ 3 of the lateral friction force value and the standard deviation ⁇ 3 of the lateral friction force value are calculated; it is understandable What’s more, in the normal distribution, the proportion within the range of ⁇ 3 ⁇ 3 ⁇ 3 accounts for 99.73% of the total, and it is statistically considered that ⁇ 5% is a small probability event, and the probability of falling outside the range of ⁇ 3 ⁇ 3 ⁇ 3 is 0.27%, belonging to If there is a small probability event, it can be considered that the data point falls outside the range of ⁇ 3 ⁇ 3 ⁇ 3, indicating that the welding process is abnormal and can be judged as an unqualified product.
  • the reference value range of the lateral friction force can be determined as ( ⁇ 3-3 ⁇ 3) ⁇ ( ⁇ 3+3 ⁇ 3) (including the endpoint value), that is, the upper limit of the reference value range of the lateral friction force is ( ⁇ 3+3 ⁇ 3), and the lower limit is ( ⁇ 3-3 ⁇ 3).
  • the upper limit and lower limit are set at The control module 112 is sufficient; similarly, the reference value range of the longitudinal welding pressure is determined as ( ⁇ 4-3 ⁇ 4) ⁇ ( ⁇ 4+3 ⁇ 4) (including the endpoint value), that is, the upper limit of the reference value range of the longitudinal welding pressure is ( ⁇ 4+3 ⁇ 4), the lower limit is ( ⁇ 4-3 ⁇ 4), and the upper limit and the lower limit can be set in the control module 112, and details are not repeated here.
  • another type of reference value range can be obtained. It can be understood that when the control module 112 determines whether the transverse friction force and the longitudinal welding pressure of the welding workpiece meet the requirements, the transverse friction force can be combined with the two types of transverse friction force at the same time. Comparison of reference value ranges. Similarly, the longitudinal welding pressure is compared with the two types of reference value ranges of longitudinal welding pressure to further improve the accuracy of welding quality inspection. Of course, one of the reference value ranges can also be selected and set at in the control module 112.
  • control module 112 of the fourth aspect of the application, and the control module 112 may be any control board, control box, control chip, and the like.
  • control module 112 includes one or more processors 1122 and a memory 1121.
  • processors 1122 and a memory 1121 are used as an example.
  • the memory 1121 can be used to store non-transitory software programs and non-transitory computer-executable programs.
  • the processor 1122 runs the non-transitory software stored in the memory 1121.
  • Programs and instructions are used to implement the welding quality detection method in the third aspect of the present application. For example, steps S100 to S400, steps S310 to S320, etc. in the above description are performed.
  • a computer-readable storage medium stores computer-executable instructions, and the computer-executable instructions are executed by one or more processors 1122 to enable the processors 1122 to execute the above-mentioned present invention.
  • the welding quality detection method in the embodiment of the third aspect of the application for example, executes steps S100 to S400, steps S310 to S320, etc. in the above description.
  • Computer storage media include, but are not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disk (DVD) or other optical disk storage, magnetic cartridges, magnetic tape, magnetic disk storage or other magnetic storage devices, or may Any other medium used to store desired information and which can be accessed by a computer.
  • communication media typically embodies computer readable instructions, data structures, program modules, or other data in a modulated data signal such as a carrier wave or other transport mechanism, and can include any information delivery media, as is well known to those of ordinary skill in the art .

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Abstract

本申请公开了焊接质量检测系统及超声波焊接设备、焊接质量检测方法，焊接质量检测系统包括检测模块、控制模块和显示模块，检测模块用于采集焊接工件的横向摩擦力和纵向焊接压力；控制模块与检测模块电性连接，控制模块用于接收并分析处理检测模块的横向摩擦力信号和纵向压力信号；显示模块与控制模块电性连接，显示模块用于显示控制模块的分析结果。本申请能有效检测焊接工件的焊接质量，及时发现焊接缺陷。

Description

焊接质量检测系统及超声波焊接设备、焊接质量检测方法
相关申请的交叉引用
本申请要求于2021年02月26日提交中国国家知识产权局的申请号为CN202110216871.7、名称为“焊接质量检测系统及超声波焊接设备、焊接质量检测方法”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请涉及超声波焊接技术领域，尤其是涉及焊接质量检测系统及超声波焊接设备、焊接质量检测方法。
背景技术
超声波金属焊接机用于将两个或两个以上的工件进行焊接，会因待焊接工件表面质量差异，如表面光洁度、油污、粉尘等，导致焊接中的剪切力或摩擦力发生变化，其中，影响摩擦力的因素包括材料选择(例如铜或铝成分，及其纯度)、表面涂层、极耳或线束之间油脂、添加剂和污垢、材料的储存环境和时间、材料的表面损伤、以及纵向焊接压力，从而影响焊接质量(焊接强度)，如虚焊、拉力不足等问题。
超声波金属焊接机对多个工件进行焊接时，超声波振动传递到受压的金属薄片上，切向振动清洁材料表面油污和分解氧化物，给多层金属薄片间创造干净的接触，此时电子在该接触面上共享两侧原子形成连接，然而大多数焊接缺陷很难在失效前被识别，因缺陷导致的成本较高，因此有必要对焊接质量进行有效检测。
发明内容
本申请的目的在于至少解决现有技术中存在的技术问题之一。
为此，本申请提供一种能够有效检测焊接工件的焊接质量，及时发现焊接缺陷的焊接质量检测系统。
本申请还提供一种安装有上述焊接质量检测系统的超声波焊接设备。
本申请还提供一种焊接质量检测系统的焊接质量检测方法。
根据本申请第一方面实施例的焊接质量检测系统，包括：检测模块，用于采集焊接工件的横向摩擦力和纵向焊接压力；控制模块，所述控制模块与所述检测模块电性连接，所述控制模块用于接收并分析处理所述检测模块的横向摩擦力信号和纵向焊接压力信号；显示模块，与所述控制模块电性连接，所述显示模块用于显示所述控制模块的分析结果。
上述技术方案至少具有如下有益效果：通过检测模块实时采集焊接工件的横向摩擦力和纵向焊接压力，并由控制模块接收检测模块的信号并对焊接工件的横向摩擦力和纵向焊接压力进行分析处理，以判断焊接工件是否为良品，并将分析结果显示于显示模块，及时 反馈到操作人员，因此，能够及时判断焊接工件的焊接质量情况，提前发现存在焊接缺陷的工件，避免后期因缺陷而产生安全隐患或造成成本浪费。
根据本申请的一些实施例，所述检测模块设置为多维力传感器，所述多维力传感器用于采集焊接工件的横向摩擦力和纵向焊接压力并分别转换为模拟电压信号，能够准确检测多个方向上的力值。
根据本申请的一些实施例，所述显示模块设置为人机界面(HMI)、计算机(PC)或指示灯，能够直观地显示分析结果。
根据本申请第二方面实施例的超声波焊接设备，包括：机座，设置有焊接基座；焊接件，沿上下方向滑动连接于所述机座，所述焊接件位于所述焊接基座的上方；驱动件，与所述焊接件连接并驱动所述焊接件沿上下方向移动；上述第一方面实施例的所述焊接质量检测系统，所述检测模块安装于所述焊接基座。
上述技术方案至少具有如下有益效果：超声波焊接设备通过检测模块实时采集焊接工件的横向摩擦力和纵向焊接压力，并由控制模块接收检测模块的信号并对焊接工件的横向摩擦力和纵向焊接压力进行分析处理，以判断焊接工件是否为良品，并将分析结果显示于显示模块，及时反馈到操作人员，因此，能够及时判断焊接工件的焊接质量情况，提前发现存在焊接缺陷的工件，避免后期因缺陷而产生安全隐患或造成成本浪费。
根据本申请第三方面实施例的用于超声波焊接设备的焊接质量检测系统的焊接质量检测方法，所述焊接质量检测系统包括检测模块、控制模块和显示模块，所述检测模块用于采集焊接工件的横向摩擦力和纵向焊接压力；所述控制模块与所述检测模块电性连接，所述控制模块用于接收并分析处理所述检测模块的横向摩擦力信号和纵向焊接压力信号；所述显示模块与所述控制模块电性连接，所述显示模块用于显示所述控制模块的分析结果，所述焊接质量检测方法包括以下步骤：分别获取横向摩擦力和纵向焊接压力的基准值范围，并将所述基准值范围设定于所述控制模块；通过所述检测模块实时采集焊接工件的横向摩擦力和纵向焊接压力并以电信号形式分别传输到所述控制模块；所述控制模块将横向摩擦力和纵向焊接压力分别与对应的基准值范围进行比较；所述控制模块将分析结果传输到所述显示模块并由所述显示模块显示所述分析结果。
上述技术方案至少具有如下有益效果：通过检测模块实时采集焊接工件的横向摩擦力和纵向焊接压力，并由控制模块接收检测模块的信号并将焊接工件的横向摩擦力和纵向焊接压力分别与对应的基准值范围进行比较，以判断焊接工件是否为良品，并将分析结果显示于显示模块，及时反馈到操作人员，因此，能够及时判断焊接工件的焊接质量情况，提前发现存在焊接缺陷的工件，避免后期因缺陷而产生安全隐患或造成成本浪费。
根据本申请的一些实施例，所述分别获取横向摩擦力和纵向焊接压力的基准值范围的 过程包括以下步骤：采集小批量样品焊接工件的横向摩擦力和纵向焊接压力；对每个样品焊接工件分别进行质量分析；记录样品焊接工件为良品的横向摩擦力和纵向焊接压力；计算横向摩擦力的平均值μ1和偏差值D1，计算纵向焊接压力的平均值μ2和偏差值D2；根据平均值μ1和偏差值D1确定横向摩擦力的基准值范围，根据平均值μ2和偏差值D2确定纵向焊接压力的基准值范围，以获取准确的基准值范围。
根据本申请的一些实施例，所述质量分析过程包括拉力测试和微观结构分析，能够准确判断样品焊接工件的焊接质量。
根据本申请的一些实施例，所述分别获取横向摩擦力和纵向焊接压力的基准值范围的过程包括以下步骤：采集小批量样品焊接工件的横向摩擦力和纵向焊接压力；采用正态分布统计方法对样品焊接工件的横向摩擦力和纵向焊接压力分别进行整理；将距横向摩擦力平均值三个标准差内的数值范围确定为横向摩擦力的基准值范围，将距纵向焊接压力平均值三个标准差内的数值范围确定为纵向焊接压力的基准值范围，能够获取另一种类型的基准值范围，进一步提高焊接质量检测的准确性。
根据本申请的一些实施例，所述采用正态分布统计方法对样品焊接工件的横向摩擦力和纵向焊接压力分别进行整理包括统计横向摩擦力数值和纵向焊接压力数值的数量并分别绘制正态分布图，计算横向摩擦力的平均值和标准差以及计算纵向焊接压力的平均值和标准差。
根据本申请的一些实施例，所述控制模块将横向摩擦力和纵向焊接压力分别与对应的基准值范围进行比较包括以下步骤：将实时采集的横向摩擦力与横向摩擦力的基准值范围比较，将实时采集的纵向焊接压力与纵向焊接压力的基准值范围比较；若横向摩擦力超出横向摩擦力基准值范围和/或纵向焊接压力超出纵向焊接压力基准值范围则判定为不合格品，若横向摩擦力在横向摩擦力基准值范围内且纵向焊接压力在纵向焊接压力基准值范围内则判定为良品。
本申请的附加方面和优点将在下面的描述中部分给出，部分将从下面的描述中变得明显，或通过本申请的实践了解到。
附图说明
本申请的上述和/或附加方面和优点从结合下面附图对实施例的描述中将变得明显和容易理解，其中：
图1为本申请实施例中焊接质量检测系统的系统架构图；
图2为本申请实施例中超声波焊接设备的结构示意图；
图3为本申请第一实施例中焊接质量检测方法的工艺步骤图；
图4为图3中步骤S100的具体工艺步骤图；
图5为图3中步骤S300的具体工艺步骤图；
图6为本申请第二实施例中焊接质量检测方法中的步骤S100的具体工艺步骤图；
图7为本申请实施例中控制模块的系统架构图。
附图标记：
超声波焊接设备100；
焊接质量检测系统110，检测模块111，控制模块112，存储器1121，处理器1122，显示模块113；
机座120，焊接基座121；
焊接件130，换能器131，调幅器132，焊头133；
驱动件140。
具体实施方式
本部分将详细描述本申请的具体实施例，本申请之较佳实施例在附图中示出，附图的作用在于用图形补充说明书文字部分的描述，使人能够直观地、形象地理解本申请的每个技术特征和整体技术方案，但其不能理解为对本申请保护范围的限制。
在本申请的描述中，需要理解的是，涉及到方位描述，例如上、下、前、后、左、右等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本申请和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本申请的限制。
在本申请的描述中，若干的含义是一个或者多个，多个的含义是两个以上，大于、小于、超过等理解为不包括本数，以上、以下、以内等理解为包括本数。如果有描述到第一、第二只是用于区分技术特征为目的，而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量或者隐含指明所指示的技术特征的先后关系。
本申请的描述中，除非另有明确的限定，设置、安装、连接等词语应做广义理解，所属技术领域技术人员可以结合技术方案的具体内容合理确定上述词语在本申请中的具体含义。
参照图1，为本申请第一方面的一些实施例提供一种焊接质量检测系统110，安装于超声波焊接设备100上，焊接质量检测系统110包括检测模块111、控制模块112和显示模块113，控制模块112与检测模块111电性连接，显示模块113与控制模块112电性连接。
在一些实施例中，检测模块111设置为多维力传感器，多维力传感器能够检测多个方向上的力值，本实施中，多维力传感器采集焊接工件的横向摩擦力和纵向焊接压力，其中，超声波焊接过程中，超声振动为横向位移，在水平方向上产生交变的剪切力，该剪切力与两个焊接工件之间的摩擦力相等，因此即为横向摩擦力，而焊接件130对焊接工件在竖直 方向上的下压力即为纵向焊接压力；一般而言，多维力传感器采集横向摩擦力和纵向焊接压力后将其转化为模拟电压信号并放大，以便传输到控制模块112上，因此实现准确采集焊接工件的横向摩擦力和纵向焊接压力；控制模块112接收到检测模块111的横向摩擦力和纵向焊接压力的模拟信号后，对其进行分析处理，控制模块112为可编程控制器(PLC)或单片机等，通过程序转换处理获得对应的力值，以便与基准值范围进行比较并得出分析结果，即焊接工件是否为良品，并将分析结果传输到显示模块113，显示模块113为人机界面(HMI)或计算机(PC)等终端设备，能够将分析结果以文字形式直观地显示出来，以直观地将分析结果反馈到操作人员；当然，可以理解的是，显示模块113还可显示焊接工件的横向摩擦力数值和纵向焊接压力数值、以及基准值范围，进一步提高分析结果的直观性；显示模块113还可以是指示灯，通过灯光颜色显示分析结果，如焊接工件为良品，则显示绿光，焊接工件为不合格品，则显示红光，此处不对显示模块113的实现形式作具体限定。
本实施例提供的技术方案中，通过检测模块111实时采集焊接工件的横向摩擦力和纵向焊接压力，并由控制模块112接收检测模块111的信号并对焊接工件的横向摩擦力和纵向焊接压力进行分析处理，以判断焊接工件是否为良品，并将分析结果显示于显示模块113，及时反馈到操作人员，因此，能够及时判断焊接工件的焊接质量情况，提前发现存在焊接缺陷的工件，避免后期因缺陷而产生安全隐患或造成成本浪费。
参照图2，为本申请第二方面的超声波焊接设备100，包括机座120、焊接件130、驱动件140和上述的焊接质量检测系统110，机座120设置有焊接基座121，焊接基座121用于定位两个焊接工件，焊接件130沿上下方向滑动连接于机座120，焊接件130设置为三联组，包括沿水平方向依次连接的换能器131、调幅器132和焊头133，其中，焊头133位于焊接基座121的正上方，驱动件140固定安装于机座120，驱动件140为气缸或其他驱动缸，驱动件140的驱动轴与焊接件130连接并驱动焊接件130沿上下方向移动，实现对工件的焊接，焊接质量检测系统110中的检测模块111(即多维力传感器)安装于焊接基座121，焊接时，两个工件的端部以对接的形式放置于焊接基座121，驱动件140驱动焊接件130向下移动，使焊头133抵压于两个工件的接合处，通过超声波振动实现焊接，一方面，焊头133下压时对工件产生竖直方向上的下压力，即纵向焊接压力，另一方面，超声波振动过程中在水平方向上产生交变的剪切力，该剪切力与两个工件之间的摩擦力相等，即为横向摩擦力，以上两个力受材料、工件表面的涂层等因素影响，通过以上两个力可判断焊接的稳定性和焊接质量；焊接过程中，检测模块111(多维力传感器)实时采集焊接工件的横向摩擦力和纵向焊接压力，并分别转换为模拟电压信号传输到控制模块112，控制模块112接收到检测模块111的模拟电压信号后，对信号进行分析处理，以及时判断焊接工件是 否为良品，并将分析结果传输到显示模块113，直观地将分析结果反馈到操作人员，因此，能够及时判断焊接工件的焊接质量情况，提前发现存在焊接缺陷的工件，避免后期因缺陷而产生安全隐患或造成成本浪费。
参照图3至图5，为本申请第三方面的焊接质量检测方法，并应用于图2的超声波焊接设备100及图1的焊接质量检测系统110中，本实施例中的焊接质量检测方法可由本申请一些实施例中的焊接质量检测系统110中的检测模块111、控制模块112和显示模块113实现，以实时检测焊接工件的焊接质量并判断焊接工件是否为良品，提前发现存在焊接缺陷的工件。需要说明的是，下述描述仅是示例性说明，而不是对申请的具体限制。
参照图3，为本申请中的焊接质量检方法的第一实施例，包括以下步骤：
步骤S100：分别获取横向摩擦力和纵向焊接压力的基准值范围，并将基准值范围设定于控制模块112；
步骤S200：通过检测模块111实时采集焊接工件的横向摩擦力和纵向焊接压力并以电信号形式分别传输到控制模块112；
步骤S300：控制模块112将横向摩擦力和纵向焊接压力分别与对应的基准值范围进行比较；
步骤S400：控制模块112将分析结果传输到显示模块113并由显示模块113显示分析结果。
本实施例提供的技术方案中，将提前获取的横向摩擦力基准值范围和纵向焊接压力基准值范围设定于控制模块112中，检测模块111(即多维力传感器)采集焊接过程中焊接工件的横向摩擦力和纵向焊接压力并转换为模拟电压信号，控制模块112接收由检测模块111传输的模拟电压信号，经程序转换为相应的力值，因此，能够与预先设定的基准值范围进行比较，以判断焊接工件是否为良品，并将结果传输到显示模块113，直观地将结果反馈到操作人员，从而操作人员能够及时判断焊接工件的焊接质量情况，提前发现存在焊接缺陷的工件，避免后期因缺陷而产生安全隐患或造成成本浪费。
参照图4，基于上述实施例，步骤S100中，分别获取横向摩擦力和纵向焊接压力的基准值范围的过程包括以下步骤：
步骤S110：采集小批量样品焊接工件的横向摩擦力和纵向焊接压力；
步骤S120：对每个样品焊接工件分别进行质量分析；
步骤S130：记录样品焊接工件为良品的横向摩擦力和纵向焊接压力；
步骤S140：计算横向摩擦力的平均值μ1和偏差值D1，计算纵向焊接压力的平均值μ2和偏差值D2；
步骤S150：根据平均值μ1和偏差值D1确定横向摩擦力的基准值范围，根据平均值μ 2和偏差值D2确定纵向焊接压力的基准值范围。
通过为良品的样品焊接工件的数据来计算基准值范围，并确定基准值范围的上限值和下限值，进而能够准确判断焊接工件的焊接质量，且上下限比较法能够快速判断焊接工件的焊接参数是否符合要求。
在一些实施例中，将样品焊接工件为良品的横向摩擦力求和后取平均值μ1，良品样品焊接工件中的最大横向摩擦力与平均值μ1之间的差值和最小横向摩擦力与平均值μ1之间的差值中，取较小者作为偏差值D1，则横向摩擦力的基准值范围为(μ1-D1)～(μ1+D1)(包含端点值)，即横向摩擦力的基准值范围的上限值为(μ1+D1)，下限值为(μ1-D1)，将上限值和下限值设定于控制模块112即可；当然，可以理解的是，根据客户要求或现场工艺要求，可选择两倍偏差2D1或三倍偏差3D1或其他倍数偏差区间范围作为横向摩擦力的基准值范围，即横向摩擦力的基准值范围为(μ1-2D1)～(μ1+2D1)(包含端点值)，对应横向摩擦力的基准值范围的上限值为(μ1+2D1)，下限值为(μ1-2D1)，或横向摩擦力的基准值范围为(μ1-3D1)～(μ1+3D1)(包含端点值)，对应横向摩擦力的基准值范围的上限值为(μ1+3D1)，下限值为(μ1-3D1)，或其他；同理可获得纵向焊接压力的基准值范围为(μ2-D2)～(μ2+D2)(包含端点值)，即纵向焊接压力的基准值范围的上限值为(μ2+D2)，下限值为(μ2-D2)，将上限值和下限值设定于控制模块112即可，此处不再赘述，同样可选择两倍偏差2D2或三倍偏差3D2或其他倍数偏差区间范围作为纵向焊接压力的基准值范围，此处不再赘述。
基于上述实施例，步骤S120中，对每个样品焊接工件分别进行质量分析包括拉力测试和微观结构分析，其中，拉力测试则通过焊接拉力试验机拉扯两个已焊接的工件，以检验焊接工件的断裂韧性，即焊接后两个工件能承受的拉力值是否满足行业标准规定的或客户规定的极限值要求；微观结构分析则通过专业的精密仪器观察焊缝或焊点的结构，并测定焊缝或焊点的参数，如残留面积等，判断焊缝或焊点的参数是否满足行业标准规定或客户规定；若拉力值和焊缝或焊接的参数均满足要求，则判定该样品焊接工件为良品，记录该良品的横向摩擦力和纵向摩擦力，否则判定该样品为不合格品。
参照图5，基于上述实施例，步骤S300中，控制模块112将横向摩擦力和纵向焊接压力分别与对应的基准值范围进行比较包括以下步骤：
步骤S310：将实时采集的横向摩擦力与横向摩擦力的基准值范围比较，将实时采集的纵向焊接压力与纵向焊接压力的基准值范围比较；
步骤S320：若横向摩擦力超出横向摩擦力基准值范围和/或纵向焊接压力超出纵向焊接压力基准值范围则判定为不合格品，若横向摩擦力在横向摩擦力基准值范围内且纵向焊接压力在纵向焊接压力基准值范围内则判定为良品。
通过将焊接过程中的力值与基准值范围比较的方法，快速判断焊接工件是否为良品，效率高。
在一些实施例中，检测模块111实时采集焊接工件的横向摩擦力和纵向焊接压力并转化为模拟电压信号，控制模块112接收横向摩擦力和纵向焊接压力的模拟电压信号后，经程序转换为可识别的横向摩擦力和纵向焊接压力数值，将横向摩擦力数值与横向摩擦力的基准值范围作比较，即将横向摩擦力数值与横向摩擦力的基准值范围的上限值和下限值作比较，将纵向焊接压力数值与纵向焊接压力的基准值范围作比较，即将纵向焊接压力数值与纵向焊接压力的基准值范围的上限值和下限值作比较，以下两个条件中：1)横向摩擦力数值在横向摩擦力的基准值范围内，包含恰好为横向摩擦力的基准值范围的端点值的情况；2)纵向焊接压力的数值在纵向焊接压力的基准值范围内，包含恰好为纵向焊接压力的基准值范围的端点值的情况；若两个条件同时满足，则判定焊接工件为良品，并将分析结果传输到显示模块113中，显示模块113中显示“合格”；若只满足其中一个条件或两个条件均不满足，则判定焊接工件为不合格品，并将分析结果传输到显示模块113中，显示模块113显示“不合格”。
通过上下限值比较的方法，能够快速判定焊接工件的焊接质量，并直观地并将分析结果显示于显示模块113，及时反馈到操作人员，以及时判断焊接工件的焊接质量情况，提前发现存在焊接缺陷的工件，避免后期因缺陷而产生安全隐患或造成成本浪费。
参照图6，根据本申请中的焊接质量检方法的第二实施例，除步骤S100中分别获取横向摩擦力和纵向焊接压力的基准值范围的过程与第一实施例不同外，其余与第一实施例相同，此处不再赘述。
第二实施例中，步骤S100中，分别获取横向摩擦力和纵向焊接压力的基准值范围的过程包括以下步骤：
S160：采集小批量样品焊接工件的横向摩擦力和纵向焊接压力；
S170：采用正态分布统计方法对样品焊接工件的横向摩擦力和纵向焊接压力分别进行整理；
S180：将距横向摩擦力平均值三个标准差内的数值范围确定为横向摩擦力的基准值范围，将距纵向焊接压力平均值三个标准差内的数值范围确定为纵向焊接压力的基准值范围。
通过正态分布统计方法获取基准值范围，能够获取另一种类型的基准值范围，进一步提高焊接质量检测的准确性。
在一些实施例中，将全部样品的横向摩擦力数值分类统计数量，以横向摩擦力的数值为横坐标，数值对应的样品数量为纵坐标，将全部样品的数据点描绘在坐标系中，当样品数据量足够大时，横向摩擦力数值符合正态分布，从而可得到横向摩擦力的正态分布图， 并计算横向摩擦力数值的平均值μ3，横向摩擦力数值的标准差σ3；可以理解的是，在正态分布中，μ3±3σ3范围内的比例占全部的99.73％，统计学上认为≤5％是小概率事件，而落在μ3±3σ3范围之外的概率是0.27％，属于小概率事件，则可认为数据点落在μ3±3σ3范围之外，表明焊接过程异常，可判定为不合格品，因此，可将横向摩擦力的基准值范围确定为(μ3-3σ3)～(μ3+3σ3)(包含端点值)，即横向摩擦力的基准值范围的上限值为(μ3+3σ3)，下限值为(μ3-3σ3)，将上限值和下限值设定于控制模块112即可；同理可得，纵向焊接压力的基准值范围确定为(μ4-3σ4)～(μ4+3σ4)(包含端点值)，即纵向焊接压力的基准值范围的上限值为(μ4+3σ4)，下限值为(μ4-3σ4)，将上限值和下限值设定于控制模块112即可，此处不再赘述。因此，可获得另一类型的基准值范围，可以理解的是，控制模块112判定焊接工件的横向摩擦力和纵向焊接压力是否满足要求时，可以将横向摩擦力同时与横向摩擦力的两种类型基准值范围比较，同样，将纵向焊接压力同时与纵向焊接压力的两种类型基准值范围比较，进一步提高焊接质量检测的准确性，当然，也可选取其中一种类型的基准值范围设定于控制模块112中。
参照图7，为本申请第四方面的控制模块112，该控制模块112可以是任控制板、控制盒、控制芯片等。
具体地，控制模块112包括一个或多个处理器1122和存储器1121，本实施例以一个处理器1122和存储器1121为例。存储器1121可用于存储非暂态软件程序以及非暂态性计算机可执行程序，如本申请第三方面实施例中的焊接质量检测方法，处理器1122通过运行存储在存储器1121中的非暂态软件程序以及指令，从而实现上述本申请第三方面实施例中的焊接质量检测方法，例如，执行上述描述中步骤S100～步骤S400，步骤S310～步骤S320等。
本申请的第五方面，提供计算机可读存储介质，该计算机可读存储介质存储有计算机可执行指令，该计算机可执行指令被一个或多个处理器1122执行，可使处理器1122执行上述本申请第三方面实施例中的焊接质量检测方法，例如，执行上述描述中步骤S100～步骤S400，步骤S310～步骤S320等。
本领域普通技术人员可以理解，上文中所公开方法中的全部或某些步骤、系统可以被实施为软件、固件、硬件及其适当的组合。某些物理组件或所有物理组件可以被实施为处理器，如中央处理器、数字信号处理器或微处理器执行的软件，或者被实施为硬件，或者被实施为集成电路，如专用集成电路。这样的软件可以分布在计算机可读介质上，计算机可读介质可以包括计算机存储介质(或非暂时性介质)和通信介质(或暂时性介质)。如本领域普通技术人员公知的，术语计算机存储介质包括在用于存储信息(诸如计算机可读指令、数据结构、程序模块或其他数据)的任何方法或技术中实施的易失性和非易失性、可移除和不可移除介质。计算机存储介质包括但不限于RAM、ROM、EEPROM、闪存或其 他存储器技术、CD-ROM、数字多功能盘(DVD)或其他光盘存储、磁盒、磁带、磁盘存储或其他磁存储装置、或者可以用于存储期望的信息并且可以被计算机访问的任何其他的介质。此外，本领域普通技术人员公知的是，通信介质通常包含计算机可读指令、数据结构、程序模块或者诸如载波或其他传输机制之类的调制数据信号中的其他数据，并且可包括任何信息递送介质。
上面结合附图对本申请实施例作了详细说明，但是本申请不限于上述实施例，在所述技术领域普通技术人员所具备的知识范围内，还可以在不脱离本申请宗旨的前提下作出各种变化。

Claims (10)

  1. 焊接质量检测系统，其特征在于，包括：
    检测模块，用于采集焊接工件的横向摩擦力和纵向焊接压力；
    控制模块，所述控制模块与所述检测模块电性连接，所述控制模块用于接收并分析处理所述检测模块的横向摩擦力信号和纵向焊接压力信号；
    显示模块，与所述控制模块电性连接，所述显示模块用于显示所述控制模块的分析结果。
  2. 根据权利要求1所述的焊接质量检测系统，其特征在于，所述检测模块设置为多维力传感器，所述多维力传感器用于采集焊接工件的横向摩擦力和纵向焊接压力并分别转换为模拟电压信号。
  3. 根据权利要求1所述的焊接质量检测系统，其特征在于，所述显示模块设置为人机界面(HMI)、计算机(PC)或指示灯。
  4. 超声波焊接设备，其特征在于，包括：
    机座，设置有焊接基座；
    焊接件，沿上下方向滑动连接于所述机座，所述焊接件位于所述焊接基座的上方；
    驱动件，与所述焊接件连接并驱动所述焊接件沿上下方向移动；
    如权利要求1～3中任一所述的焊接质量检测系统，所述检测模块安装于所述焊接基座。
  5. 一种焊接质量检测方法，用于超声波焊接设备的焊接质量检测系统中，其特征在于，所述焊接质量检测系统包括检测模块、控制模块和显示模块，所述检测模块用于采集焊接工件的横向摩擦力和纵向焊接压力；所述控制模块与所述检测模块电性连接，所述控制模块用于接收并分析处理所述检测模块的横向摩擦力信号和纵向焊接压力信号；所述显示模块与所述控制模块电性连接，所述显示模块用于显示所述控制模块的分析结果，所述焊接质量检测方法包括以下步骤：
    分别获取横向摩擦力和纵向焊接压力的基准值范围，并将所述基准值范围设定于所述控制模块；
    通过所述检测模块实时采集焊接工件的横向摩擦力和纵向焊接压力并以电信号形式分别传输到所述控制模块；
    所述控制模块将横向摩擦力和纵向焊接压力分别与对应的基准值范围进行比较；
    所述控制模块将分析结果传输到所述显示模块并由所述显示模块显示所述分析结果。
  6. 根据权利要求5所述的焊接质量检测方法，其特征在于，所述分别获取横向摩擦力和纵向焊接压力的基准值范围的过程包括以下步骤：
    采集小批量样品焊接工件的横向摩擦力和纵向焊接压力；
    对每个样品焊接工件分别进行质量分析；
    记录样品焊接工件为良品的横向摩擦力和纵向焊接压力；
    计算横向摩擦力的平均值μ1和偏差值D1，计算纵向焊接压力的平均值μ2和偏差值D2；
    根据平均值μ1和偏差值D1确定横向摩擦力的基准值范围，根据平均值μ2和偏差值D2确定纵向焊接压力的基准值范围。
  7. 根据权利要求6所述的焊接质量检测方法，其特征在于，所述质量分析包括拉力测试和微观结构分析。
  8. 根据权利要求5所述的焊接质量检测方法，其特征在于，所述分别获取横向摩擦力和纵向焊接压力的基准值范围的过程包括以下步骤：
    采集小批量样品焊接工件的横向摩擦力和纵向焊接压力；
    采用正态分布统计方法对样品焊接工件的横向摩擦力和纵向焊接压力分别进行整理；
    将距横向摩擦力平均值三个标准差内的数值范围确定为横向摩擦力的基准值范围，将距纵向焊接压力平均值三个标准差内的数值范围确定为纵向焊接压力的基准值范围。
  9. 根据权利要求8所述的焊接质量检测方法，其特征在于，所述采用正态分布统计方法对样品焊接工件的横向摩擦力和纵向焊接压力分别进行整理包括统计横向摩擦力数值和纵向焊接压力数值的数量并分别绘制正态分布图，计算横向摩擦力的平均值和标准差以及计算纵向焊接压力的平均值和标准差。
  10. 根据权利要求5所述的焊接质量检测方法，其特征在于，所述控制模块将横向摩擦力和纵向焊接压力分别与对应的基准值范围进行比较包括以下步骤：
    将实时采集的横向摩擦力与横向摩擦力的基准值范围比较，将实时采集的纵向焊接压力与纵向焊接压力的基准值范围比较；
    若横向摩擦力超出横向摩擦力基准值范围和/或纵向焊接压力超出纵向焊接压力基准值范围则判定为不合格品，若横向摩擦力在横向摩擦力基准值范围内且纵向焊接压力在纵向焊接压力基准值范围内则判定为良品。
PCT/CN2022/078040 2021-02-26 2022-02-25 焊接质量检测系统及超声波焊接设备、焊接质量检测方法 WO2022179626A1 (zh)

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CN114406526B (zh) * 2021-12-14 2024-05-10 深圳顺络电子股份有限公司 焊接机及焊接方法
CN116818534A (zh) * 2023-08-30 2023-09-29 江铃汽车股份有限公司 一种波峰焊焊接质量检测方法及装置
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