CN114310047B - Intelligent control method and system for welding machine - Google Patents
Intelligent control method and system for welding machine Download PDFInfo
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- CN114310047B CN114310047B CN202111667776.5A CN202111667776A CN114310047B CN 114310047 B CN114310047 B CN 114310047B CN 202111667776 A CN202111667776 A CN 202111667776A CN 114310047 B CN114310047 B CN 114310047B
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Abstract
The application relates to an intelligent control method and system of a welding machine, belonging to the technical field of welding equipment, wherein the method comprises the following steps: acquiring a processing sequence table of workpieces; acquiring the type of a workpiece to be welded at present as the type of the current workpiece; acquiring a welding temperature corresponding to the current workpiece type as a current welding temperature; acquiring the actual welding number of the workpieces corresponding to the current workpiece type; acquiring the number of workpieces corresponding to the current workpiece type as the current workpiece number; judging whether the actual welding quantity is equal to the current workpiece quantity or not; if so, acquiring the next workpiece type as a subsequent workpiece type; acquiring corresponding welding temperature based on the type of the subsequent workpiece, and taking the welding temperature as the subsequent welding temperature; and controlling the welding machine to weld the workpieces corresponding to the subsequent workpiece types based on the subsequent welding temperature. The intelligent welding machine has the advantages that the intelligent degree of the welding process of the welding machine is improved, and the complexity in the operation process is reduced.
Description
Technical Field
The application relates to the technical field of welding equipment, in particular to an intelligent control method and system of a welding machine.
Background
The welding machine comprises a metal welding machine and a hot melting welding machine, wherein the metal welding machine is mainly used for welding metal products, and the hot melting welding machine is mainly used for welding plastic workpieces. However, both of them melt the connecting part of the welding part and the welded part by high temperature, and after the place where the welding part and the welded part are melted and contacted with each other is cooled, a complete welding workpiece can be formed.
In the use process of the existing welding machine, due to the fact that the materials of workpieces are different, in the welding process, an operator manually adjusts the welding temperature of the welding machine according to the welding temperatures of different welding workpieces, and therefore welding of different workpieces is achieved.
However, the method often requires manual adjustment of the welding temperature, and has low intelligence degree and troublesome operation.
Disclosure of Invention
In order to improve the intelligent degree of the welding machine in the welding process and reduce the complexity of the welding machine in the operation process, the application provides an intelligent control method and system of the welding machine.
On the one hand, the application provides an intelligent control method of a welding machine, which adopts the following technical scheme:
an intelligent control method of a welder, comprising:
acquiring a processing sequence table of workpieces, wherein the processing sequence table comprises workpiece types, the number of the workpieces corresponding to the workpiece types and welding temperatures corresponding to the workpiece types;
acquiring the type of the workpiece which is welded at present as the current type of the workpiece;
acquiring the welding temperature corresponding to the current workpiece type as the current welding temperature;
acquiring the actual welding number of the workpieces corresponding to the current workpiece type;
acquiring the number of workpieces corresponding to the current workpiece type as the current workpiece number;
judging whether the actual welding quantity is equal to the current workpiece quantity or not;
if not, acquiring the continuous processing quantity based on the actual welding quantity and the current workpiece quantity;
controlling the welding machine to weld the workpiece corresponding to the current workpiece type based on the number of continuous processing and the current welding temperature;
if so, acquiring the next workpiece type as a subsequent workpiece type;
acquiring a corresponding welding temperature based on the subsequent workpiece type as a subsequent welding temperature;
generating a temperature adjustment instruction based on the subsequent welding temperature;
controlling a welding temperature of the welder to be equal to the subsequent welding temperature based on the tempering instruction;
controlling the welder to weld the workpiece corresponding to the subsequent workpiece type based on the subsequent welding temperature.
By adopting the technical scheme, the workpiece type, the corresponding workpiece quantity and the welding temperature can be obtained by obtaining the processing sequence table of the workpieces, then the current workpiece type and the current welding temperature corresponding to the current workpiece type are obtained, then the actual welding quantity of the workpieces of the current workpiece type is obtained, whether the actual welding quantity is equal to the obtained current workpiece quantity is judged, if not, the continuous processing quantity is obtained according to the actual welding quantity and the current workpiece quantity, and then the workpieces corresponding to the current workpiece type are continuously welded according to the continuous processing quantity and the current welding temperature. And if so, acquiring the next workpiece type as the subsequent workpiece type, acquiring the corresponding welding temperature as the subsequent welding temperature according to the subsequent workpiece type, then generating a temperature regulating instruction according to the subsequent welding temperature, controlling the welding temperature of the welding machine to be equal to the subsequent welding temperature according to the temperature regulating instruction, and finally enabling the welding machine to weld the corresponding workpiece according to the subsequent welding temperature. Therefore, the welding temperature can be adjusted according to the type and the number of the workpieces, the intelligent degree of the welding machine in the welding process can be improved, and the complexity of the operation process is reduced.
Preferably, the acquiring the processing sequence table of the workpiece further includes:
acquiring the current arrangement sequence of the preprocessed workpieces;
judging whether the current arrangement sequence is matched with the processing sequence table;
if not, generating abnormal sequencing information;
and adjusting the current arrangement sequence based on the abnormal sequencing information.
By adopting the technical scheme, whether the current arrangement sequence is matched with the processing sequence table is judged, so that whether the current arrangement sequence of the workpieces is correct is judged, if not, the current arrangement sequence is proved to be inconsistent with the workpiece sequence of the processing sequence table, and abnormal sequencing information is generated, so that an operator is reminded to adjust the current arrangement sequence of the workpieces, and the accuracy of the welding machine for welding the workpieces can be improved.
Preferably, the adjusting the current ranking order based on the sorting exception information includes the following steps:
acquiring an abnormal position image based on the sorting abnormal information;
acquiring an exception type based on the exception position image, wherein the exception type comprises quantity exception and sequence exception;
when the abnormal type is abnormal in quantity, acquiring the current quantity of the corresponding workpieces based on the abnormal position image;
acquiring and outputting an augmented number based on the corresponding number of workpieces and the current number;
adjusting the current ranking order based on the augmentation quantity;
when the abnormal type is sequence abnormality, acquiring the current sequence of the corresponding workpieces based on the abnormal position image;
acquiring and outputting adjustment information based on the current sequence and the arrangement sequence of the processing sequence table;
and adjusting the current arrangement sequence based on the adjustment information.
By adopting the technical scheme, the abnormal type is obtained according to the position image, and when the quantity is judged to be abnormal, the supplement quantity can be obtained according to the quantity of the workpieces and the current quantity, and the workpieces are supplemented according to the supplement quantity. When the sequence is judged to be abnormal, the adjustment information is obtained according to the current sequence and the arrangement sequence of the processing sequence table, so that the reason of the abnormality can be accurately obtained, and the accuracy of adjustment is improved.
Preferably, after the generating the sorting exception information, the method further includes:
acquiring a stop instruction;
controlling the welder to stop working based on the stop command.
By adopting the technical scheme, the welding machine is controlled to stop working according to the stop instruction, the possibility of welding error of the welding machine on the workpiece caused by wrong sequencing of the workpiece can be reduced, the welding quality of the workpiece can be ensured as much as possible, and the welding error rate is reduced.
Preferably, after the controlling the welder to stop working based on the stop instruction further comprises:
acquiring a confirmation image of the preprocessed workpiece;
acquiring the current arrangement sequence based on the confirmation image to be used as a final arrangement sequence;
judging whether the final arrangement sequence is matched with the processing sequence table;
if yes, generating a welding instruction;
and controlling the welder to continue working based on the welding instruction.
By adopting the technical scheme, the final arrangement sequence is obtained according to the confirmation image, whether the final arrangement sequence is matched with the processing sequence table or not is judged, whether the arrangement sequence of the workpieces is correct or not can be judged, if yes, a welding instruction is generated to continue working with the air welding machine, and the intelligent degree of the welding machine can be further improved.
Preferably, the controlling the welding temperature of the welder to be equal to the subsequent welding temperature based on the temperature adjustment instruction further comprises:
acquiring the actual welding temperature of the welding machine;
judging whether the actual welding temperature is equal to the subsequent welding temperature or not;
if not, alarm information is generated and output.
Through adopting above-mentioned technical scheme, judge whether actual welding temperature equals follow-up welding temperature, can judge whether the actual welding temperature of welding machine can reach the welding requirement, if not, then generate and output alarm information to remind relevant operating personnel, conveniently in time investigate the reason that the problem produced, and then reduce the welding fault rate of welding machine, guarantee welded effect as far as.
Preferably, the generating and outputting the alarm information includes the following steps:
acquiring welding current of the welding machine;
judging whether the welding current is equal to a current threshold value or not, and obtaining a first judgment result;
when the first judgment result is yes, acquiring the welding voltage of the welding machine;
judging whether the welding voltage is equal to a voltage threshold value or not, and obtaining a second judgment result;
if the second judgment result is yes, generating and outputting an equipment abnormity prompt;
and outputting a circuit abnormity prompt when the first judgment result is negative or the second judgment result is negative.
By adopting the technical scheme, whether the welding current is equal to the current threshold value or not is judged, the first judgment result is obtained, whether the welding temperature abnormity of the welding machine is caused by the abnormal current or not can be judged, if the welding temperature abnormity is caused by the abnormal current, whether the welding voltage is equal to the voltage threshold value or not is judged, the second judgment result is obtained, if the welding temperature abnormity is caused by the abnormal equipment, the abnormal welding temperature is proved to be possibly caused by the abnormal equipment, and the abnormal prompt of the circuit is output at the moment. And when one of the first judgment result and the second judgment result is negative, the fact that the welding temperature is abnormal is proved to be caused by circuit abnormality with high probability, and the circuit abnormality prompt is output at the moment. Therefore, the reason for the welding abnormity can be further judged, and the judgment accuracy is further improved.
Preferably, the acquiring the processing order table of the workpiece further includes:
acquiring the maximum welding temperature of the welding machine;
obtaining a melting point of the workpiece to be processed;
judging whether the maximum welding temperature is greater than or equal to the melting point;
if not, generating replacement information;
and if so, acquiring the processing sequence table.
By adopting the technical scheme, whether the maximum welding temperature of the welding machine is greater than or equal to the melting point of the workpiece or not is judged, and whether the welding machine can weld the workpiece or not can be judged. If not, the welding machine is proved to be incapable of welding the workpiece, and at the moment, replacement information is generated to remind an operator to replace the welding machine; if so, the welding machine can be used normally, and the processing sequence table is continuously acquired at the moment to perform subsequent operation. Therefore, the functions of the welding machine can be screened, the welding machine can be ensured to normally weld the workpiece as far as possible, and the working efficiency is improved.
In a second aspect, the present application provides an intelligent control system for a welding machine, which adopts the following technical scheme:
an intelligent control system for a welding machine, comprising:
the list acquisition module is used for acquiring a processing sequence list of workpieces, wherein the processing sequence list comprises workpiece types, the number of the workpieces corresponding to the workpiece types and welding temperatures corresponding to the workpiece types;
the first type acquisition module is used for acquiring the type of the workpiece which is currently welded as the current type of the workpiece;
the first temperature acquisition module is used for acquiring the welding temperature corresponding to the current workpiece type as the current welding temperature;
a first quantity obtaining module, configured to obtain an actual welding quantity of the workpiece corresponding to the current workpiece type;
the second quantity acquisition module is used for acquiring the quantity of the workpieces corresponding to the current workpiece type as the current workpiece quantity;
the quantity judging module is used for judging whether the actual welding quantity is equal to the current workpiece quantity or not;
a third quantity obtaining module, configured to obtain a machining continuation quantity based on the actual welding quantity and the current workpiece quantity when the actual welding quantity is not equal to the current workpiece quantity;
a first control module, configured to control the welding machine to weld the workpiece corresponding to the current workpiece type based on the number of machining passes and the current welding temperature;
a second type obtaining module, configured to obtain a next workpiece type as a subsequent workpiece type when the actual welding number is equal to the current workpiece number;
the second temperature acquisition module is used for acquiring corresponding welding temperature based on the subsequent workpiece type to serve as the subsequent welding temperature;
the instruction generating module is used for generating a temperature adjusting instruction based on the subsequent welding temperature;
a temperature adjustment module to control a welding temperature of the welder to be equal to the subsequent welding temperature based on the temperature adjustment instruction;
and the second control module is used for controlling the welding machine to weld the workpieces corresponding to the subsequent workpiece types based on the subsequent welding temperature.
By adopting the technical scheme, the list acquisition module acquires the processing sequence list of the workpieces and sends the processing sequence list to the first type acquisition module, the first temperature acquisition module and the second quantity acquisition module. The first type acquisition module acquires a current working type and sends the current working type to the first temperature acquisition module, the first quantity acquisition module and the second quantity acquisition module, and the first temperature acquisition module acquires a current welding temperature corresponding to the current workpiece type and sends the current welding temperature to the first control module. The number judging module judges whether the actual welding number is equal to the current workpiece number or not and sends a judged result to the third number obtaining module and the second type obtaining module.
When the actual welding quantity is not equal to the current workpiece quantity, the third quantity obtaining module obtains the continuous machining quantity according to the actual welding quantity and the current workpiece quantity and sends the continuous machining quantity to the first control module, and the first control module controls the welding machine to weld the workpieces according to the continuous machining quantity and the current welding temperature.
When the actual welding number is equal to the current workpiece number, the second type obtaining module obtains the subsequent workpiece types and sends the subsequent workpiece types to the second temperature obtaining module, the second temperature obtaining module obtains corresponding subsequent welding temperatures and sends the subsequent welding temperatures to the instruction generating module, the instruction generating module generates a temperature adjusting instruction based on the subsequent welding temperatures and sends the temperature adjusting instruction to the temperature adjusting module, the temperature adjusting module controls the welding temperature of the welding machine to be equal to the subsequent welding temperatures according to the temperature adjusting instruction and sends the adjusting result to the second control module, and the second control module controls the welding machine to weld the corresponding workpieces according to the subsequent welding temperatures. Therefore, the welding temperature can be adjusted according to the type and the number of workpieces, the intelligent degree of the welding machine in the welding process can be improved, and the complexity of the operation process is reduced.
In summary, the present application includes at least one of the following beneficial technical effects:
1. and welding the workpieces according to the current welding temperature and the creep machining quantity, and controlling a welding machine to weld the workpieces of the subsequent workpiece types according to the subsequent workpiece types and the subsequent welding temperature after the current workpiece types are machined. Therefore, the welding temperature can be adjusted according to the type and the number of the workpieces, the intelligent degree of the welding machine in the welding process can be improved, and the complexity of the operation process is reduced;
2. and judging whether the current arrangement sequence is matched with the processing sequence table or not, so as to judge whether the current arrangement sequence of the workpieces is correct or not, if not, proving that the current arrangement sequence is inconsistent with the workpiece sequence of the processing sequence table, and generating abnormal sequencing information at the moment, so as to remind an operator to adjust the current arrangement sequence of the workpieces, thereby improving the accuracy of the welding machine for welding the workpieces.
Drawings
FIG. 1 is a schematic overall flow chart diagram of an intelligent control method for a welding machine according to an embodiment of the present application;
FIG. 2 is a schematic flow chart of steps S21 to S25 before step S1 according to an embodiment of the present application;
FIG. 3 is a schematic flowchart of steps S31 to S34 after step S1 according to an embodiment of the present application;
FIG. 4 is a detailed flowchart of steps S41 to S48, i.e., step S34, in one embodiment of the present application;
FIG. 5 is a schematic flowchart of steps S51 to S52 after step S33 according to an embodiment of the present application;
FIG. 6 is a schematic flow chart of the embodiment of the present application after step S52, i.e., step S61 to step S65;
FIG. 7 is a schematic flow chart of the embodiment of the present application after step S12, i.e., from step S71 to step S73;
FIG. 8 is a detailed flowchart of steps S81 to S86, i.e., step S73, according to an embodiment of the present application;
FIG. 9 is a block diagram of a configuration of an intelligent control system of a welding machine according to an embodiment of the present application.
Description of reference numerals:
1. a list acquisition module; 2. a first type acquisition module; 3. a first temperature acquisition module; 4. a first quantity acquisition module; 5. a second quantity acquisition module; 6. a quantity judgment module; 7. a third quantity obtaining module; 8. a first control module; 9. a second type obtaining module; 10. a second temperature acquisition module; 11. an instruction generation module; 12. a temperature adjustment module; 13. and a second control module.
Detailed Description
The present application is described in further detail below with reference to figures 1-9.
The embodiment of the application discloses an intelligent control method of a welding machine.
Referring to fig. 1, an intelligent control method of a welding machine includes:
s1, acquiring a processing sequence table of a workpiece;
s2, acquiring the type of a workpiece to be welded at present as the type of the current workpiece;
s3, acquiring a welding temperature corresponding to the current workpiece type as the current welding temperature;
s4, acquiring the actual welding number of the workpieces corresponding to the current workpiece type;
s5, acquiring the number of workpieces corresponding to the current workpiece type as the current workpiece number;
s6, judging whether the actual welding quantity is equal to the current workpiece quantity or not;
s7, if not, acquiring the continuous machining quantity based on the actual welding quantity and the current workpiece quantity;
s8, controlling a welding machine to weld the workpiece corresponding to the current workpiece type based on the number of continuous processing and the current welding temperature;
s9, if yes, acquiring the next workpiece type as a subsequent workpiece type;
s10, acquiring corresponding welding temperature based on the type of the subsequent workpiece, and taking the welding temperature as the subsequent welding temperature;
s11, generating a temperature adjusting instruction based on the subsequent welding temperature;
s12, controlling the welding temperature of the welding machine to be equal to the subsequent welding temperature based on the temperature adjusting instruction;
and S13, controlling a welding machine to weld the workpiece corresponding to the type of the subsequent workpiece based on the subsequent welding temperature.
When the welding machine welds multiple types of work pieces, place the work piece of the same type together and weld usually, carry out the welded in-process to the work piece of different grade type, the welding temperature of welding machine is also different, carries out comparatively intelligent regulation in order to make things convenient for the welding temperature to the welding machine, at first acquires the processing sequence table of work piece. The processing sequence table in step S1 includes a workpiece type, a workpiece number corresponding to the workpiece type, and a welding temperature corresponding to the workpiece type. The processing sequence table can be data which is stored in an intelligent controller of the welding machine in advance after different types of workpieces are sequenced according to the processing types of the workpieces. When workpieces of different types are sequenced, the sequence is the same as that in the processing sequence table.
Step S2 is executed to acquire the type of the workpiece currently being welded as the current workpiece type, that is, the type of the workpiece to be welded initially when all workpieces start welding, and the acquisition mode may be acquired by shooting with a camera or manually input into a controller by an operator.
And then, executing the step S3, namely acquiring the welding temperature corresponding to the current workpiece type as the current welding temperature, wherein the acquisition mode is to match the current workpiece type with the workpiece types in the processing sequence table, and after the matching is successful, acquiring the corresponding welding temperature, namely the current welding temperature. And then, acquiring the actual welding number of the workpieces corresponding to the current workpiece type, wherein the acquiring mode can be a mode of counting through a counter, or a mode of taking corresponding pictures through a camera and acquiring the welding number of the workpieces by using the pictures. And then acquiring the number of workpieces corresponding to the current workpiece type as the current number of workpieces according to the same acquisition mode as the current welding temperature.
At this time, whether the actual welding number is equal to the current workpiece number is judged, that is, whether the welding of the workpiece corresponding to the current workpiece type is completed is judged. If not, namely the actual welding quantity is not equal to the current workpiece quantity, obtaining the continuous processing quantity according to the actual welding quantity and the current workpiece quantity, namely subtracting the actual welding quantity from the current workpiece quantity to obtain a value, namely the continuous processing quantity. And then controlling the welding machine to weld the workpieces corresponding to the current workpiece type according to the number of the continuous processing and the current welding temperature, namely controlling the welding machine to weld the number of the workpieces equal to the number of the continuous processing according to the current welding temperature, thereby completing the welding of the workpieces corresponding to the current workpiece type.
If so, namely the actual welding number is equal to the current workpiece number, the workpiece corresponding to the current workpiece type is proved to be welded, the next workpiece type is obtained at the moment and is used as the subsequent workpiece type, namely the next workpiece type of the current workpiece type in the processing sequence table is obtained, and then the welding temperature corresponding to the subsequent workpiece type is obtained as the subsequent welding temperature in the same obtaining mode of obtaining the current welding temperature.
And then generating a temperature regulating instruction according to the subsequent welding temperature, and controlling the welding temperature of the welding machine to be equal to the subsequent welding temperature according to the temperature regulating instruction, namely increasing or decreasing the temperature of a heater of the welding machine according to the temperature regulating instruction to enable the welding temperature to be equal to the subsequent welding temperature. The temperature adjustment instruction can be obtained according to the welding temperatures of different types of workpieces, for example, if the current welding temperature is greater than the subsequent welding temperature, a value obtained by subtracting the subsequent welding temperature from the current welding temperature is a cooling value, the temperature adjustment instruction is a cooling instruction, and the cooling amplitude is the size of the cooling value. On the contrary, if the current welding temperature is lower than the subsequent welding temperature, the value obtained by subtracting the current welding temperature from the subsequent welding temperature is a temperature rise value, the temperature regulation instruction is a temperature rise instruction at the moment, and the temperature rise amplitude is the size of the temperature rise value.
And finally, controlling the welding machine to weld the workpieces corresponding to the types of the subsequent workpieces according to the subsequent welding temperature control, so that the welding temperature can be automatically adjusted according to the types and the number of the workpieces, the times of manual participation can be reduced, the intelligent degree in the welding process of the welding machine is improved, and the complexity in the operation process is further reduced.
Referring to fig. 2, before selecting a welding machine, it is necessary to consider that the welding machine can weld workpieces, that is, determine whether the welding machine can melt the corresponding workpieces, and therefore, in another embodiment, step S1 includes the following steps before acquiring the processing sequence table of the workpieces:
s21, acquiring the maximum welding temperature of the welding machine;
s22, obtaining a melting point of a workpiece to be processed;
s23, judging whether the maximum welding temperature is greater than or equal to the melting point;
s24, if not, generating replacement information;
and S25, if so, acquiring a processing sequence table.
Specifically, the maximum welding temperature of the welding machine is firstly obtained, the maximum welding temperature may be data prestored in a controller, and then the melting point of the workpiece to be machined is obtained, and the obtaining mode may be a mode manually input by an operator, or a corresponding melting point may be obtained through a connection network according to the type and material of the workpiece.
And then judging whether the maximum welding temperature is greater than or equal to the melting point, namely judging whether the maximum welding temperature of the welding machine can melt the workpiece, and judging whether the welding machine can weld the workpiece to be processed. If not, the welding machine is proved to be incapable of melting the workpiece, and the replacement information is generated and output and can be output to the display, so that the operator is reminded to replace the corresponding welding machine in time, and the workpiece can be guaranteed to be normally melted and welded. If so, the welder is proven to be able to melt the workpiece, at which point the next step, namely step S1, of obtaining a machining sequence table, can be continued. Therefore, the welding machine can be screened, the welding machine can be ensured to normally weld the workpiece as far as possible, and the welding efficiency of the workpiece is further improved.
Referring to fig. 3, after workpieces to be processed are sorted according to types, because the workpieces are manually placed on a feeding mechanism of a welding machine in the sorting of the workpieces, a sequential placing error may exist in the placing process of the workpieces, and therefore, in another embodiment, after obtaining the processing sequence table of the workpieces, the step S1 further includes the following steps:
s31, acquiring the current arrangement sequence of the preprocessed workpieces;
s32, judging whether the current arrangement sequence is matched with a processing sequence table;
s33, if not, generating abnormal sequencing information;
and S34, adjusting the current arrangement sequence based on the abnormal arrangement information.
Specifically, the current arrangement sequence of the pre-processed workpieces is obtained, images can be obtained through shooting by a camera in an obtaining mode, whether the current arrangement sequence is matched with the processing sequence table or not is judged, the matching mode can be that the shot images are compared with pre-stored images, and the pre-stored images are the workpiece images with the same arrangement sequence of the workpieces in the processing sequence table. And judging whether the two images are the same through an image algorithm, if so, proving that the current arrangement sequence is matched with the processing sequence table, otherwise, proving that the current arrangement sequence is not matched with the processing sequence table.
When the current arrangement sequence is matched with the processing sequence table, the welder is proved to be capable of continuing the welding operation. If not, namely the current arrangement sequence is not matched with the processing sequence, abnormal arrangement information is generated and output to a display screen, and then the operator is reminded according to the abnormal arrangement information, so that the operator can adjust the current arrangement sequence, namely the arrangement sequence of the workpieces, and the current arrangement sequence is matched with the processing sequence table, and the accuracy of the welding machine for the workpieces can be improved. Meanwhile, the adjustment mode of the arrangement sequence can also be performed through a control system, for example, corresponding labels are arranged on the workpieces, the labels are realized through RFC, the labels are obtained through scanning the RFC, and then the manipulator adjusts the sequence of the workpieces.
Referring to fig. 4, in another embodiment, the step S34 of adjusting the current ranking order based on the ranking abnormality information includes the steps of:
s41, acquiring an abnormal position image based on the sorting abnormal information;
s42, acquiring an abnormal type based on the abnormal position image;
s43, when the abnormal type is abnormal in quantity, acquiring the current quantity of the corresponding workpieces based on the abnormal position image;
s44, acquiring and outputting the supplement quantity based on the corresponding workpiece quantity and the current quantity;
s45, adjusting the current arrangement sequence based on the supplement quantity;
s46, when the abnormal type is sequence abnormality, acquiring the current sequence of the corresponding workpieces based on the abnormal position image;
s47, acquiring and outputting adjustment information based on the current sequence and the arrangement sequence of the processing sequence table;
and S48, adjusting the current arrangement sequence based on the adjustment information.
Specifically, when the arrangement sequence of the workpieces is wrong, the abnormal position image is acquired according to the sorting abnormal information, namely, after the shot image is compared with the pre-stored image, the acquired shot image is different from the pre-stored image, and then the abnormal position image is acquired.
And acquiring an abnormal type according to the abnormal position image, wherein the abnormal type comprises quantity abnormality and sequence abnormality, the quantity abnormality is the same type of workpieces, the quantity of the workpieces placed on the welding machine is different from that of the workpieces in the processing sequence table, and the sequence abnormality is the arrangement sequence of the workpieces of different types is different from that in the processing sequence table. The abnormal type may be obtained through manual judgment, or through other methods, such as image recognition.
When the abnormal type is judged to be abnormal in quantity, namely the quantity of the workpieces in the same type at the same position of the shot image and the pre-stored image is different, the current quantity of the corresponding workpieces is obtained according to the abnormal position image, namely the quantity of the workpieces with abnormal quantity. And then acquiring and outputting the supplementary number according to the corresponding number of the workpieces and the current number, namely acquiring the difference value between the number of the workpieces and the current number, wherein the corresponding number of the workpieces is the number of the workpieces of the workpiece type corresponding to the workpiece type with abnormal number in the processing sequence table.
And then, adjusting the arrangement sequence according to the supplement quantity, namely displaying the supplement quantity through a display screen, thereby reminding an operator to supplement the corresponding workpieces according to the supplement quantity and enabling the current quantity of the workpieces to be equal to the quantity of the workpieces in the processing sequence table.
When the abnormality type is a sequence abnormality, namely the arrangement sequence of the workpieces in the shot image is different from the arrangement sequence of the workpieces in the pre-stored image, the current sequence of the corresponding workpieces is acquired according to the abnormal position image. And then outputting adjustment information according to the current sequence and the arrangement sequence of the workpieces in the processing sequence table, wherein the adjustment information can be prompt information for adjusting the current sequence according to the sequencing sequence in the processing sequence table.
And then, reminding an operator to adjust the current arrangement sequence according to the adjustment information, namely, the operator adjusts the current sequence according to the arrangement sequence in the processing sequence table to ensure that the current sequence is the same as the sequencing sequence in the processing sequence table, so that the reason for the abnormality can be accurately acquired by the method, and the adjustment accuracy is improved.
Furthermore, when the exception type includes both quantity exception and sequence exception, the quantity exception may be adjusted first and then the sequence exception, or the sequence exception may be adjusted first and then the quantity exception is adjusted, so as to further improve the accuracy of the adjustment.
Referring to fig. 5, in order to prevent a welding error of the workpieces and reduce a welding error rate of the workpieces after the sorting of the workpieces is abnormal, in another embodiment, the step S33 further includes the following steps after the sorting abnormal information is generated:
s51, acquiring a stop instruction;
and S52, controlling the welding machine to stop working based on the stop instruction.
Specifically, after the sequencing abnormal information is generated, a stop instruction is obtained, the stop instruction can be automatically generated by a controller, and then the welding machine is controlled to stop working according to the stop instruction, namely the heating function and the driving function of the welding machine are controlled to stop acting according to the stop instruction, so that the possibility of welding error of the welding machine on the workpiece caused by sequencing error of the workpiece can be reduced, the welding quality of the workpiece can be ensured as much as possible, and the welding error rate is reduced.
Referring to fig. 6, after the welder stops working and the alignment of the workpieces is adjusted, in order to facilitate the start of the welder, in another embodiment, the step S52 further includes the following steps after controlling the welder to stop working based on the stop command:
s61, acquiring a confirmation image of the preprocessed workpiece;
s62, acquiring a current arrangement sequence based on the confirmed image to serve as a final arrangement sequence;
s63, judging whether the final arrangement sequence is matched with a processing sequence table or not;
s64, if yes, generating a welding instruction;
and S65, controlling the welding machine to continue working based on the welding instruction.
Specifically, a confirmation image of the pre-processed workpiece, that is, an image of the workpiece after the current arrangement order is adjusted, is obtained in the same manner as the confirmation image is obtained by shooting through the camera. And then acquiring the current arrangement sequence according to the confirmation image to be used as a final arrangement sequence, and then judging whether the final arrangement sequence is matched with the processing sequence table or not, wherein the judging mode is the same as the mode for judging whether the current arrangement sequence is matched with the processing sequence or not, so that whether the arrangement sequence of the adjusted workpiece is correct or not can be judged.
If yes, the final arrangement sequence is matched with the processing sequence table, a welding instruction is generated at the moment, the welding machine is controlled to continue to work based on the welding instruction, the heating function and the driving function of the welding machine are controlled to restart according to the welding instruction, the welding machine is enabled to continue to work, and therefore the intelligent degree of the welding machine can be further improved.
Referring to fig. 7, after the welding temperature of the welder is adjusted according to the temperature adjustment command, the actual welding temperature of the welder may be different from the temperature of the control adjustment, and therefore, in another embodiment, the step S12 of controlling the welding temperature of the welder to be equal to the subsequent welding temperature based on the temperature adjustment command further includes the following steps:
s71, acquiring the actual welding temperature of the welding machine;
s72, judging whether the actual welding temperature is equal to the subsequent welding temperature or not;
and S73, if not, generating and outputting alarm information.
The method comprises the steps of obtaining the actual welding temperature of a welding machine in a temperature sensor or infrared image mode, namely obtaining the temperature of a welding head of the welding machine, and then judging whether the actual welding temperature is equal to the subsequent welding temperature or not, namely judging whether the temperature of the welding head can reach the subsequent welding temperature or not to weld the workpiece corresponding to the type of the subsequent workpiece.
If not, namely the actual welding temperature is inconsistent with the subsequent welding temperature, the welding quality of the workpiece may be influenced in the process that the welding machine welds the workpiece, and alarm information is generated and output at the moment, so that an operator is reminded, the operator can timely overhaul the welding machine, the reason of problem generation is conveniently and timely checked, the welding error rate of the welding machine is reduced, and the welding effect is guaranteed as much as possible.
Referring to fig. 8, in order to further determine the cause of the problem of the welding machine, in another embodiment, the step S73 of generating and outputting the alarm information includes the following steps:
s81, obtaining welding current of a welding machine;
s82, judging whether the welding current is equal to a current threshold value or not, and obtaining a first judgment result;
s83, when the first judgment result is yes, obtaining a welding voltage of a welding machine;
s84, judging whether the welding voltage is equal to a voltage threshold value or not, and obtaining a second judgment result;
s85, when the second judgment result is yes, generating and outputting an equipment abnormity prompt;
s86, when the first judgment result is negative or the second judgment result is negative, outputting a circuit abnormity prompt.
Specifically, the welding current of the welding machine is obtained, the obtaining mode of the welding current can be obtained through measurement of an ammeter, then whether the welding current is equal to a current threshold value or not is judged, and a first judgment result is obtained, namely whether the welding temperature abnormality of the welding machine is caused by too large or too small current or not is judged.
If the first judgment result is yes, namely the welding current is proved to be equal to the current threshold, the welding temperature abnormity of the welding machine is proved not to be caused by overlarge or undersize current, the welding voltage of the welding machine is obtained at the moment, the obtaining mode can be obtained through measurement of a voltmeter, the welding voltage is compared with the voltage threshold, whether the welding voltage and the voltage threshold are equal or not is judged, and a second judgment result is obtained, namely whether the welding temperature abnormity of the welding machine is caused by overlarge or undersize voltage or not is judged.
If the second judgment result is yes, the temperature abnormity is proved to be caused by current abnormity or voltage abnormity, the problem of the welding head of the welding machine is proved probably at the moment, and the abnormity prompt of the equipment is generated and output, so that the equipment can be conveniently checked by maintenance personnel.
And when any one of the first judgment result or the second judgment result is negative, the welding temperature abnormity is proved to be caused by circuit abnormity, and the circuit abnormity prompt is output at the moment, so that maintenance personnel can conveniently check the circuit. Therefore, the reason for the abnormal welding can be further judged, and the judgment accuracy is further improved.
The implementation principle of the intelligent control method of the welding machine in the embodiment of the application is as follows: the method comprises the steps of obtaining a processing sequence table of workpieces, obtaining workpiece types, the number of the corresponding workpieces and welding temperatures, obtaining the current workpiece types and the current welding temperatures corresponding to the current workpiece types, obtaining the actual welding number of the workpieces of the current workpiece types, judging whether the actual welding number is equal to the obtained current workpiece number, obtaining continuous processing number according to the actual welding number and the current workpiece number if the actual welding number is not equal to the obtained current workpiece number, and continuously welding the workpieces corresponding to the current workpiece types according to the continuous processing number and the current welding temperatures. If the welding temperature is equal to the subsequent welding temperature, the next workpiece type is obtained as the subsequent workpiece type, the corresponding welding temperature is obtained as the subsequent welding temperature according to the subsequent workpiece type, then a temperature adjusting instruction is generated according to the subsequent welding temperature, the welding temperature of the welding machine is controlled to be equal to the subsequent welding temperature according to the temperature adjusting instruction, and finally the welding machine is enabled to weld the corresponding workpiece according to the subsequent welding temperature. Therefore, the welding temperature can be adjusted according to the type and the number of workpieces, the intelligent degree of the welding machine in the welding process can be improved, and the complexity of the operation process is reduced.
The embodiment of the application also discloses an intelligent control system of the welding machine, which can achieve the same technical effect as the intelligent control method of the welding machine.
Referring to fig. 9, an intelligent control system of a welding machine includes:
the list acquisition module 1 is used for acquiring a processing sequence list of workpieces, wherein the processing sequence list comprises workpiece types, the number of the workpieces corresponding to the workpiece types and welding temperatures corresponding to the workpiece types;
the first type acquisition module 2 is used for acquiring the type of a workpiece which is currently welded and taking the type of the workpiece as the current type of the workpiece;
the first temperature acquisition module 3 is used for acquiring the welding temperature corresponding to the current workpiece type as the current welding temperature;
a first quantity obtaining module 4, configured to obtain an actual welding quantity of workpieces corresponding to a current workpiece type;
a second quantity obtaining module 5, for obtaining the quantity of the workpieces corresponding to the current workpiece type as the current workpiece quantity;
the quantity judging module 6 is used for judging whether the actual welding quantity is equal to the current workpiece quantity or not;
a third quantity obtaining module 7, configured to obtain a machining continuation quantity based on the actual welding quantity and the current workpiece quantity when the actual welding quantity is not equal to the current workpiece quantity;
the first control module 8 is used for controlling the welding machine to weld the workpiece corresponding to the current workpiece type based on the number of continuous processing and the current welding temperature;
a second type obtaining module 9, configured to obtain a next workpiece type as a subsequent workpiece type when the actual welding number is equal to the current workpiece number;
a second temperature obtaining module 10, configured to obtain a corresponding welding temperature based on a subsequent workpiece type, as a subsequent welding temperature;
the instruction generating module 11 is configured to generate a temperature adjusting instruction based on the subsequent welding temperature;
the temperature adjusting module 12 is used for controlling the welding temperature of the welding machine to be equal to the subsequent welding temperature based on the temperature adjusting instruction;
and the second control module 13 is used for controlling the welding machine to weld the workpieces corresponding to the subsequent workpiece types based on the subsequent welding temperature.
Specifically, the list acquiring module 1 acquires a processing sequence list of the workpieces and sends the processing sequence list to the first type acquiring module 2, the first temperature acquiring module 3 and the second quantity acquiring module 5. The first type obtaining module 2 obtains the current working type and sends the current working type to the first temperature obtaining module 3, the first quantity obtaining module 4 and the second quantity obtaining module 5. The processing sequence table comprises a workpiece type, the number of workpieces corresponding to the workpiece type and welding temperature corresponding to the workpiece type.
The first temperature obtaining module 3 obtains a welding temperature corresponding to a current workpiece type as a current welding temperature and sends the welding temperature to the first control module 8, the first quantity obtaining module 4 obtains the workpiece type corresponding to the current workpiece type as an actual welding quantity and sends the actual welding quantity to the quantity judging module 6, the second quantity obtaining module 5 obtains the workpiece quantity corresponding to the current workpiece type as a current workpiece quantity and sends the current workpiece quantity to the quantity judging module 6, the quantity judging module 6 judges whether the actual welding quantity is equal to the current workpiece quantity or not, and sends a judged result to the third quantity obtaining module 7 and the second type obtaining module 9.
When the actual welding number is not equal to the current number of workpieces, the third number obtaining module 7 obtains the number of continuous processing according to the actual welding number and the current number of workpieces and sends the number of continuous processing to the first control module 8, and the first control module 8 controls the welding machine to weld the workpieces according to the number of continuous processing and the current welding temperature.
When the actual welding number is equal to the current number of workpieces, the second type obtaining module 9 obtains the next workpiece type as a subsequent workpiece type and sends the subsequent workpiece type to the second temperature obtaining module 10, and the second temperature obtaining module 10 obtains the welding temperature corresponding to the subsequent workpiece type as a subsequent welding temperature and sends the subsequent welding temperature to the instruction generating module 11.
The instruction generating module 11 generates a temperature adjusting instruction based on the subsequent welding temperature and sends the temperature adjusting instruction to the temperature adjusting module 12, and the temperature adjusting module 12 controls the welding temperature of the welding machine to be equal to the subsequent welding temperature according to the temperature adjusting instruction and sends an adjusting result to the second control module 13. The second control module 13 controls the welding machine to weld the workpieces corresponding to the types of the subsequent workpieces according to the subsequent welding temperature. Therefore, the welding temperature can be adjusted according to the type and the number of the workpieces, the intelligent degree of the welding machine in the welding process can be improved, and the complexity of the operation process is reduced.
The above embodiments are preferred embodiments of the present application, and the protection scope of the present application is not limited by the above embodiments, so: all equivalent changes made according to the structure, shape and principle of the present application shall be covered by the protection scope of the present application.
Claims (9)
1. An intelligent control method of a welding machine, characterized by comprising:
acquiring a processing sequence table of workpieces, wherein the processing sequence table comprises workpiece types, the number of the workpieces corresponding to the workpiece types and welding temperatures corresponding to the workpiece types;
acquiring the type of the workpiece which is welded at present as the current type of the workpiece;
acquiring the welding temperature corresponding to the current workpiece type as the current welding temperature;
acquiring the actual welding number of the workpieces corresponding to the current workpiece type;
acquiring the number of the workpieces corresponding to the current workpiece type as the current workpiece number;
judging whether the actual welding quantity is equal to the current workpiece quantity or not;
if not, acquiring the number of continuous processing based on the actual welding number and the current workpiece number;
controlling the welding machine to weld the workpiece corresponding to the current workpiece type based on the number of continuous processing and the current welding temperature;
if so, acquiring the next workpiece type as a subsequent workpiece type;
acquiring a corresponding welding temperature based on the subsequent workpiece type as a subsequent welding temperature;
generating a temperature adjustment instruction based on the subsequent welding temperature;
controlling a welding temperature of the welder to be equal to the subsequent welding temperature based on the tempering instruction;
controlling the welder to weld the workpiece corresponding to the subsequent workpiece type based on the subsequent welding temperature.
2. The intelligent control method according to claim 1, wherein the obtaining of the processing order list of the workpiece further comprises:
acquiring the current arrangement sequence of the preprocessed workpieces;
judging whether the current arrangement sequence is matched with the processing sequence table;
if not, generating abnormal sorting information;
and adjusting the current arrangement sequence based on the abnormal sorting information.
3. The intelligent control method according to claim 2, wherein the adjusting the current ranking order based on the ranking abnormality information includes the steps of:
acquiring an abnormal position image based on the sequencing abnormal information;
acquiring an exception type based on the exception position image, wherein the exception type comprises a quantity exception and a sequence exception;
when the abnormal type is abnormal in quantity, acquiring the current quantity of the corresponding workpieces based on the abnormal position image;
acquiring and outputting an augmented number based on the corresponding number of workpieces and the current number;
adjusting the current ranking order based on the augmentation quantity;
when the abnormal type is sequence abnormality, acquiring the current sequence of the corresponding workpiece based on the abnormal position image;
acquiring and outputting adjustment information based on the current sequence and the arrangement sequence of the processing sequence table;
and adjusting the current arrangement sequence based on the adjustment information.
4. The intelligent control method according to claim 2, wherein the generating of the ordering exception information further comprises:
acquiring a stop instruction;
controlling the welder to stop working based on the stop command.
5. The intelligent control method of claim 4, further comprising, after the controlling the welder to stop working based on the stop command:
acquiring a confirmation image of the preprocessed workpiece;
acquiring the current arrangement sequence based on the confirmation image to be used as a final arrangement sequence;
judging whether the final arrangement sequence is matched with the processing sequence table;
if yes, generating a welding instruction;
controlling the welder to continue to work based on the welding instruction.
6. The intelligent control method of claim 1, wherein the controlling the welding temperature of the welder to equal the subsequent welding temperature based on the temperature adjustment command further comprises:
acquiring the actual welding temperature of the welding machine;
judging whether the actual welding temperature is equal to the subsequent welding temperature or not;
if not, alarm information is generated and output.
7. The intelligent control method according to claim 6, wherein the generating and outputting alarm information includes the steps of:
acquiring welding current of the welding machine;
judging whether the welding current is equal to a current threshold value or not, and obtaining a first judgment result;
when the first judgment result is yes, acquiring the welding voltage of the welding machine;
judging whether the welding voltage is equal to a voltage threshold value or not, and obtaining a second judgment result;
if the second judgment result is yes, generating and outputting an equipment abnormity prompt;
and outputting a circuit abnormity prompt when the first judgment result is negative or the second judgment result is negative.
8. The intelligent control method according to claim 1, wherein the acquiring a processing order list of the workpiece further comprises:
acquiring the maximum welding temperature of the welding machine;
obtaining a melting point of the workpiece to be processed;
judging whether the maximum welding temperature is greater than or equal to the melting point;
if not, generating replacement information;
and if so, acquiring the processing sequence table.
9. An intelligent control system of a welding machine, comprising:
the device comprises a list acquisition module (1) for acquiring a processing sequence table of workpieces, wherein the processing sequence table comprises workpiece types, the number of workpieces corresponding to the workpiece types and welding temperatures corresponding to the workpiece types;
the first type acquisition module (2) is used for acquiring the type of the workpiece which is currently welded as the current type of the workpiece;
the first temperature acquisition module (3) is used for acquiring the welding temperature corresponding to the current workpiece type as the current welding temperature;
a first number acquisition module (4) for acquiring an actual welding number of the workpieces corresponding to the current workpiece type;
a second quantity acquisition module (5) for acquiring the quantity of workpieces corresponding to the current workpiece type as the current workpiece quantity;
a quantity judging module (6) for judging whether the actual welding quantity is equal to the current workpiece quantity;
a third number obtaining module (7) for obtaining a machining continuation number based on the actual welding number and the current workpiece number when the actual welding number is not equal to the current workpiece number;
a first control module (8) for controlling the welding machine to weld the workpiece corresponding to the current workpiece type based on the number of successive machining and the current welding temperature;
a second type obtaining module (9) for obtaining the next workpiece type as a subsequent workpiece type when the actual welding number is equal to the current workpiece number;
a second temperature acquisition module (10) for acquiring a corresponding welding temperature based on the subsequent workpiece type as a subsequent welding temperature;
an instruction generation module (11) for generating a tempering instruction based on the subsequent welding temperature;
a temperature adjustment module (12) for controlling a welding temperature of the welder to be equal to the subsequent welding temperature based on the temperature adjustment instruction;
a second control module (13) to control the welder to weld the workpiece corresponding to the subsequent workpiece type based on the subsequent welding temperature.
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| CN202607135U (en) * | 2011-05-10 | 2012-12-19 | 广州东昇机械有限公司 | Welding apparatus |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US20200223004A1 (en) * | 2019-01-10 | 2020-07-16 | Hakko Corporation | Soldering Iron Control System |
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| CN202607135U (en) * | 2011-05-10 | 2012-12-19 | 广州东昇机械有限公司 | Welding apparatus |
| CN106826001A (en) * | 2015-12-03 | 2017-06-13 | 成都九十度工业产品设计有限公司 | A kind of welding control system and its control method |
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