CN116214009B - Gas flow rate control method based on welding state identification - Google Patents
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Abstract
The invention discloses a gas flow rate control method based on welding state identification, which comprises the steps of firstly collecting current and shielding gas flow rate data in a welding process in real time, and extracting a welding action starting point based on the current data; then carrying out welding state identification and judging the type of the current welding line; when the welding seam type is an independent spot welding seam, extracting a welding action termination point of the spot welding seam, matching based on a matching relation between welding current and gas flow rate, and performing gas flow control when current of a plurality of continuous spot welding seams is not matched with a gas flow rate flat shoulder value; when the weld joint type is a long weld joint, density clustering is carried out on all current points, and a current average value is calculated as a current level shoulder value based on a clustering result; meanwhile, calculating the air flow shoulder value and matching, and controlling the air flow when the matching relation is not satisfied; the invention can realize the accurate identification of different welding states and the refined air flow control effect, and solves the problem of gas waste possibly caused by unmatched air flow.
Description
Technical Field
The invention belongs to the technical field of intelligent welding, and particularly relates to a gas flow rate control method based on welding state identification.
Background
In the industrial welding process, no matter manual welding or large-scale robot welding sites are used, various welding protective gases are widely used, when the flow rate of the welding protective gases is actually set, technicians often set and adjust the flow rate of the welding protective gases manually according to past experiences, the manual setting method inevitably causes the waste of the protective gases, the production cost of manufacturing enterprises is increased intangibly, the carbon emission of the enterprises is increased, and the environment-friendly development concept of energy conservation and emission reduction is not met. Therefore, a more refined welding shielding gas flow rate control method is sought, and the production targets of enterprise cost saving, energy saving and carbon saving can be effectively achieved.
In addition, the timing of the gas flow control in different welding conditions is different, and for short and dense spot welds, frequent adjustment of the shielding gas flow rate is not desirable, while for stable long welds, it is desirable to identify as quickly as possible whether gas flow control is required and to perform gas flow control as quickly as possible. Identifying and purposefully giving control strategies for different welding conditions is therefore a major issue to be addressed.
Disclosure of Invention
The invention aims to: aiming at the problems in the background art, the invention provides a gas flow rate control method based on welding state identification, which is used for collecting high-frequency current data and shielding gas flow rate data in the welding process, firstly judging the current welding state, identifying the current welding line type, providing a gas flow control strategy for independent spot welding lines and long welding lines respectively, and giving gas flow control opportunities.
The technical scheme is as follows: a gas flow rate control method based on welding state identification, comprising the steps of:
step S1, collecting current and shielding gas flow speed data in the welding process in real time, and extracting a starting point of each welding action; setting a list current_list for registering real-time current information and a list gaspeed_list for registering protection gas flow rate information respectively, receiving data measured by a sensor and transmitting the data into the current_list and the gaspeed_list;
extracting a welding action starting point start_index in a current_list, synchronously extracting a gas flow rate point corresponding to the start_index in a corresponding gaspeed_list, and discarding a current point and a gas flow rate point before the start_index in the current_list and the gaspeed_list;
step S2, setting a spot welding judgment threshold value th_point and a judgment sliding window ws, wherein the judgment sliding window ws is larger than the spot welding judgment threshold value th_point;
current_list continuously receives current points, when the number of the current points received in the current_list is larger than th_point, the current points when the welding line is terminated are found, and when the total number of the current points when the welding line is terminated is smaller than a judgment sliding window ws, the welding line is judged to be an independent spot welding line; when the number of the current points received in the current_list is greater than or equal to ws, judging that the welding line is a long welding line;
step S3, calculating a current flat shoulder value current_shoulderer and a gas flow shoulder value gaspeed_shoulderer of each independent spot welding seam and judging the matching relation based on the matching relation between the current and the gas flow velocity in the welding process when independent spot welding occurs, and judging that the welding current is not matched with the gas flow velocity and controlling the gas flow velocity when the current_shoulderer and the gas flow velocity are not matched in a plurality of continuous independent spot welding seams;
s4, when a long welding line occurs, density clustering is carried out on all current points in the current_list; calculating a current average value of the current points gathered into one class, and taking the current average value as a current_shoulder; calculating a gaspeed_shholder and matching based on a matching relationship between current and gas flow rates in a welding process; when current_shholder does not match gaspeed_shholder, gas flow rate control is performed.
Further, the specific steps of extracting the starting point of each welding action in step S1 are as follows:
firstly judging whether the number of current points received in the current_list is equal to a preset threshold value th1 or not by taking the current data as a judging standard, and judging whether the maximum current value in the current_list exceeds a preset threshold value th2 or not when the number of current points is equal to th 1; when the maximum current value does not exceed th2, representing no welding current, discarding the existing current value in the current_list and the shielding gas flow rate value in the gasspeed_list, and continuously receiving new current and shielding gas flow rate; when the maximum current value exceeds th2, which represents that there is an effective welding current, further judgment is made: when the first value in the current_list is smaller than th2 and all currents after the maximum current value are larger than th2, extracting a first current point larger than th2 as a starting point start_index of welding action, and taking a gas flow rate point at the same position in the gaspeed_list as a gas flow rate starting point; the current value and the guard gas flow rate value before start_index in current_list and gaspeed_list are discarded, respectively.
Further, the method for searching the current point when the welding seam is terminated in the step S2 includes:
judging whether the last two current points in the current_list are smaller than a preset threshold value th2, if so, extracting the last current point larger than th2 as an end_index of the welding action, and respectively discarding the current value and the protection gas flow rate value after the end_index in the current_list and the protected_list.
Further, the specific method for calculating the current flat shoulder value current_shoulder and the gas flow flat shoulder value gaspeed_shoulder of each independent spot welding seam in the step S3 includes:
step S3.1, searching a spot welding seam starting point and a spot welding seam ending point according to the method in the steps S1-S2, and determining a welding action interval of the independent spot welding seam;
s3.2, calculating first-order differential values of two adjacent current points in a welding action interval; traversing the first-order difference value, and extracting two current points corresponding to the first-order difference value when the first-order difference value is smaller than a preset threshold th3, so as to finally obtain a current point set after the abnormality is removed for the first time; then, carrying out secondary treatment on the residual current point set by a box graph method to further remove abnormal current points; taking an average value of all the current points remained finally, namely a current shoulder value current_shunt;
calculating first-order differential values of two adjacent air flow points in the gaspeed_list by the same method; traversing the first-order difference value, and extracting two airflow points corresponding to the first-order difference value when the first-order difference value is smaller than a preset threshold th 4; further removing abnormal airflow points by a box graph method; all the flow points remaining finally are averaged and noted as the flow flat shoulder value gaspeed_shoulder.
Step S3.3, judging whether current_shholder and gaspeed_shholder in a welding action interval meet the matching relation or not based on the matching relation between welding current and gas flow rate; setting an alarm threshold warning_count, and starting counting by the warning_count when current_shholder and gaspeed_shholder are not matched;
and when detecting a current termination point, repeating the steps S3.1-S3.3, then emptying the current_ list, gasspeed _list, the current_shoulder and the gaspeed_shoulder, and starting the next detection until the rolling_count accumulation exceeds a preset threshold th5, and judging that the welding current is not matched with the gas flow rate at the moment, and controlling the gas flow rate.
Further, the specific judgment method in the step S4 is as follows:
s4.1, performing density clustering on all current points in the current_list by adopting a dbscan algorithm; setting related parameters min_samples and eps to enable the current clustering result to be clustered into one type at most; when the current points in the current_list can be gathered into one type, calculating the current average value of all the current points as the current_shpast, simultaneously calculating the gaspeed_shpast based on the method in the step S3, and judging based on the matching relation between the welding current and the gas flow rate; when the current_sholder is matched with the gaspeed_sholder, gas flow control is not needed, otherwise, the gas flow rate is needed to be controlled;
step S4.2, when all current points in the dbscan clustering result cannot be clustered into one type, eliminating a first value in current_list and gaspeed_list at the same time, receiving a new value, and repeating the step S4.1;
step S4.3, detecting a current termination point based on the method in step S2; when the current termination point is found, current_ list, gasspeed _list, current_sholder and gaspeed_sholder are emptied to represent that the welding line of the current section is ended, and the next welding line is identified.
Compared with the prior art, the technical scheme adopted by the invention has the following beneficial effects:
(1) By collecting high-frequency current data and protective gas flow rate data in the welding process and identifying the welding state based on the high-frequency current data and the protective gas flow rate data, the traditional welding seams are divided into independent spot welding seams and long welding seams, and a gas flow rate control strategy can be provided in a targeted manner, so that the welding state is finer.
(2) Aiming at independent spot welds, the invention adopts a method for continuously judging the matching condition of a plurality of welds, thereby avoiding the problem of frequent air flow control. Aiming at long welding seams, the method adopts a clustering method to calculate the current and the air flow shoulder value, so that the matching is carried out, the problem of unmatched air flow can be effectively realized in a short time, the air flow is controlled as soon as possible, and the problems of gas waste, product welding quality flaws and the like possibly caused by unmatched air flow are solved.
Drawings
Fig. 1 is a flowchart of a gas flow rate control method according to an embodiment of the present invention.
Description of the embodiments
The invention is further explained below with reference to the drawings. As shown in fig. 1, the present invention provides a gas flow rate control method based on welding state recognition,
step S1, collecting current and shielding gas flow speed data in the welding process in real time, and extracting a starting point of each welding action; the method comprises the following specific steps:
step S1.1, respectively setting a list current_list for registering real-time current information and a list gaspeed_list for registering protection gas flow rate information, receiving data measured by a sensor and transmitting the data into the current_list and the gaspeed_list; setting a current_shoulderer value and a gas flow rate flat shoulder value gaspeed_shoulderer, wherein the initial current_shoulderer and the gaspeed_shoulderer are null values;
s1.2, extracting a starting point representing a welding action in the list; in this embodiment, the current data is used as a judgment standard, and the specific judgment method is as follows:
firstly judging whether the number of current points received in the current_list is equal to a preset threshold value th1, in the embodiment, th1=4, judging whether the maximum current value in the current_list exceeds a preset threshold value th2 when the number of current points is equal to th1, in the embodiment, th2=5A, when the maximum current value does not exceed th2, representing no welding current, discarding the existing current value in the current_list and the protection gas flow rate value in the protected_list, and continuously receiving new current and protection gas flow rate; when the maximum current value exceeds th2, which represents that there is an effective welding current, further judgment is made: when the first value in the current_list is smaller than th2 and all currents after the maximum current value are larger than th2, the first current point larger than th2 is extracted to serve as a starting point start_index of welding action, and the gas flow rate point at the same position in the gaspeed_list is also taken as a gas flow rate starting point. The current value and the guard gas flow rate value before start_index in current_list and gaspeed_list are discarded, respectively.
Step S2, a spot welding judgment threshold value th_point and a judgment sliding window ws are set for judging the current welding state. Wherein the sliding window ws is judged to be larger than the spot welding judgment threshold th_point. In particular, the method comprises the steps of,
and continuously receiving the current points by the current_list, when the number of the current points received in the current_list is larger than th_point, searching the current points when the welding line is terminated, and when the total number of the current points when the welding line is terminated is smaller than the judgment sliding window ws, judging that the welding line is an independent spot welding line. And when the number of the current points received in the current_list is greater than or equal to ws, judging that the welding line is a long welding line. Ws=7 is set in this embodiment.
The method for searching the termination points of the independent spot welds is specifically as follows:
judging whether the last two current points in the current_list are smaller than a preset threshold value th2, if so, extracting the last current point larger than th2 as an end_index of the welding action, and respectively discarding the current value and the protection gas flow rate value after the end_index in the current_list and the protected_list.
Because the welding time of the independent spot welding seam is shorter, the method for judging the air flow control is essentially different from that of the continuous long welding seam, so the invention firstly carries out the welding state identification, and provides different shielding gas flow rate control strategies for different welding modes on the basis.
Step S3, for the independent spot welding state, providing the following airflow control strategy:
and step S3.1, determining a welding action interval of the independent spot welding seam according to the spot welding starting point and the spot welding ending point found in the steps S1-S2.
And S3.2, calculating first-order differential values of two adjacent current points in the welding action interval. Traversing the first-order difference value, and extracting two current points corresponding to the first-order difference value when the first-order difference value is smaller than a preset threshold th3, so as to finally obtain a current point set after the first abnormality removal. Th3=10a in this embodiment. This step aims at removing the points of the current points where the fluctuations are evident. And then, carrying out secondary treatment on the residual current point set by a box graph method, and further removing abnormal current points. And (5) taking an average value of all the current points remained finally, namely the current_shunt.
The first order difference value of two adjacent air flow points in the gaspeed_list is calculated in the same way. Traversing the first-order difference value, and extracting two airflow points corresponding to the first-order difference value when the first-order difference value is smaller than a preset threshold th 4. Th4=1 in this embodiment. And further removing abnormal airflow points by a box pattern method. All the flow points remaining finally were averaged and noted as gaspeed_shrouder.
Step S3.3, judging whether current_shholder and gaspeed_shholder in a welding action interval meet the matching relation or not based on the matching relation between welding current and gas flow rate; an alarm threshold warning_count is set, and when current_sholder and gaspeed_sholder do not match, warning_count starts counting.
And when detecting a current termination point, repeating the steps S3.1-S3.3, then emptying the current_ list, gasspeed _list, the current_shoulder and the gaspeed_shoulder, and starting the next detection until the rolling_count accumulation exceeds a preset threshold th5, and judging that the welding current is not matched with the gas flow rate at the moment, and controlling the gas flow rate. Th5=3 in this embodiment.
Step S4, providing the following airflow control strategy for the continuous long weld joint state:
and S4.1, when the number of the current points received in the current_list is greater than or equal to ws, performing density clustering on all the current points in the current_list. In this embodiment, a dbscan algorithm is used for clustering, so as to extract welding current points in a stationary stage. By setting the relevant parameters min_samples and eps, in the embodiment, eps=10, min_samples=4, i.e. at least 4 of every 7 current points are set to be in one type, so that the clustering labels only have two cases of-1 and 0, wherein a label of-1 represents unsuccessful clustering, and a label of 0 represents one type. The current average value is calculated for all the current points with the category of 0 and is taken as current_shunt. All gas flow rate points in the gaspeed_list are simultaneously calculated as described in step S3.2. Based on the matching relationship between the welding current and the gas flow rate, whether the current_shholder and the gas_shholder in the welding action interval meet the matching relationship is judged. When current_shholder matches gaspeed_shholder, no gas flow control is needed, otherwise gas flow rate control is needed.
And S4.2, when all the current points in the dbscan clustering result cannot be clustered into one type, simultaneously eliminating the first value in the current_list and the gaspeed_list, receiving a new value, and repeating the control strategy.
Step S4.3, detecting a current termination point based on the method described in step S2. When the current termination point is found, current_ list, gasspeed _list, current_share, and gaspeed_share are cleared. Representing the end of the welding line of the section, and entering the recognition of the welding line of the next section.
The foregoing is merely a preferred embodiment of the present invention and it should be noted that modifications and adaptations to those skilled in the art may be made without departing from the principles of the present invention, which are intended to be comprehended within the scope of the present invention.
Claims (5)
1. A gas flow rate control method based on welding state identification, comprising the steps of:
step S1, collecting current and shielding gas flow speed data in the welding process in real time, and extracting a starting point of each welding action; setting a list current_list for registering real-time current information and a list gaspeed_list for registering protection gas flow rate information respectively, receiving data measured by a sensor and transmitting the data into the current_list and the gaspeed_list;
extracting a welding action starting point start_index in a current_list, synchronously extracting a gas flow rate point corresponding to the start_index in a corresponding gaspeed_list, and discarding a current point and a gas flow rate point before the start_index in the current_list and the gaspeed_list;
step S2, setting a spot welding judgment threshold value th_point and a judgment sliding window ws, wherein the judgment sliding window ws is larger than the spot welding judgment threshold value th_point;
current_list continuously receives current points, when the number of the current points received in the current_list is larger than th_point, the current points when the welding line is terminated are found, and when the total number of the current points when the welding line is terminated is smaller than a judgment sliding window ws, the welding line is judged to be an independent spot welding line; when the number of the current points received in the current_list is greater than or equal to ws, judging that the welding line is a long welding line;
step S3, calculating a current flat shoulder value current_shoulderer and a gas flow shoulder value gaspeed_shoulderer of each independent spot welding seam and judging the matching relation based on the matching relation between the current and the gas flow velocity in the welding process when independent spot welding occurs, and judging that the welding current is not matched with the gas flow velocity and controlling the gas flow velocity when the current_shoulderer and the gas flow velocity are not matched in a plurality of continuous independent spot welding seams;
s4, when a long welding line occurs, density clustering is carried out on all current points in the current_list; calculating a current average value of the current points gathered into one class, and taking the current average value as a current_shoulder; calculating a gaspeed_shholder and matching based on a matching relationship between current and gas flow rates in a welding process; when current_shholder does not match gaspeed_shholder, gas flow rate control is performed.
2. The method for controlling gas flow rate based on welding state recognition according to claim 1, wherein the specific steps of extracting the starting point of each welding action in step S1 are as follows:
firstly judging whether the number of current points received in the current_list is equal to a preset threshold value th1 or not by taking the current data as a judging standard, and judging whether the maximum current value in the current_list exceeds a preset threshold value th2 or not when the number of current points is equal to th 1; when the maximum current value does not exceed th2, representing no welding current, discarding the existing current value in the current_list and the shielding gas flow rate value in the gasspeed_list, and continuously receiving new current and shielding gas flow rate; when the maximum current value exceeds th2, which represents that there is an effective welding current, further judgment is made: when the first value in the current_list is smaller than th2 and all currents after the maximum current value are larger than th2, extracting a first current point larger than th2 as a starting point start_index of welding action, and taking a gas flow rate point at the same position in the gaspeed_list as a gas flow rate starting point; the current value and the guard gas flow rate value before start_index in current_list and gaspeed_list are discarded, respectively.
3. The method for controlling gas flow rate based on welding state identification according to claim 1, wherein the method for finding the current point when the welding line is terminated in step S2 comprises:
judging whether the last two current points in the current_list are smaller than a preset threshold value th2, if so, extracting the last current point larger than th2 as an end_index of the welding action, and respectively discarding the current value and the protection gas flow rate value after the end_index in the current_list and the protected_list.
4. The method for controlling the gas flow rate based on the welding state identification according to claim 1, wherein the specific method for calculating the current flat shoulder value current_shoulder and the gas flat shoulder value gaspeed_shoulder of each individual spot welding seam in the step S3 comprises the following steps:
step S3.1, searching a spot welding seam starting point and a spot welding seam ending point according to the method in the steps S1-S2, and determining a welding action interval of the independent spot welding seam;
s3.2, calculating first-order differential values of two adjacent current points in a welding action interval; traversing the first-order difference value, and extracting two current points corresponding to the first-order difference value when the first-order difference value is smaller than a preset threshold th3, so as to finally obtain a current point set after the abnormality is removed for the first time; then, carrying out secondary treatment on the residual current point set by a box graph method to further remove abnormal current points; taking an average value of all the current points remained finally, namely a current shoulder value current_shunt;
calculating first-order differential values of two adjacent air flow points in the gaspeed_list by the same method; traversing the first-order difference value, and extracting two airflow points corresponding to the first-order difference value when the first-order difference value is smaller than a preset threshold th 4; further removing abnormal airflow points by a box graph method; taking an average value of all the final remaining airflow points, and marking the average value as an airflow average shoulder value gaspeed_shoulder;
step S3.3, judging whether current_shholder and gaspeed_shholder in a welding action interval meet the matching relation or not based on the matching relation between welding current and gas flow rate; setting an alarm threshold warning_count, and starting counting by the warning_count when current_shholder and gaspeed_shholder are not matched;
and when detecting a current termination point, repeating the steps S3.1-S3.3, then emptying the current_ list, gasspeed _list, the current_shoulder and the gaspeed_shoulder, and starting the next detection until the rolling_count accumulation exceeds a preset threshold th5, and judging that the welding current is not matched with the gas flow rate at the moment, and controlling the gas flow rate.
5. The method for controlling gas flow rate based on welding state identification according to claim 1, wherein the specific judging method in step S4 is as follows:
s4.1, performing density clustering on all current points in the current_list by adopting a dbscan algorithm; setting related parameters min_samples and eps to enable the current clustering result to be clustered into one type at most; when the current points in the current_list can be gathered into one type, calculating the current average value of all the current points as the current_shpast, simultaneously calculating the gaspeed_shpast based on the method in the step S3, and judging based on the matching relation between the welding current and the gas flow rate; when the current_sholder is matched with the gaspeed_sholder, gas flow control is not needed, otherwise, the gas flow rate is needed to be controlled;
step S4.2, when all current points in the dbscan clustering result cannot be clustered into one type, eliminating a first value in current_list and gaspeed_list at the same time, receiving a new value, and repeating the step S4.1;
step S4.3, detecting a current termination point based on the method in step S2; when the current termination point is found, current_ list, gasspeed _list, current_sholder and gaspeed_sholder are emptied to represent that the welding line of the current section is ended, and the next welding line is identified.
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| CN116441674B (en) * | 2023-06-14 | 2023-08-15 | 苏芯物联技术(南京)有限公司 | High-precision welding airflow control system and control method |
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