阅读说明：本技术 一种智能激光焊接系统以及方法 (Intelligent laser welding system and method ) 是由 郭利华 卓松生 梁奉超 李张翼 熊金猛 王利国 秦信春 于 2021-05-31 设计创作，主要内容包括：本发明涉及连续生产线激光焊接技术领域,尤其涉及一种智能激光焊接系统以及方法；该系统包括通过工业网络连接进行数据交互的激光焊机、焊缝视觉检测系统及智能焊接控制系统,焊缝视觉检测系统包括视觉传感器组、控制器和焊缝质量检测系统,视觉传感器组用于采集焊接处焊接前及焊接后的数据,并通过控制器传输给焊缝质量检测系统,焊缝质量检测系统用于检查焊缝是否合格并将数据传输给智能焊接控制系统,智能焊接控制系统用于调节以及优化激光焊接的焊接工艺参数。本发明提供的焊接系统能快速精确地检测焊缝质量并根据焊缝缺陷智能优化焊接工艺参数,提高激光焊机的智能化水平,保证生产线能够稳定、安全并连续运行。(The invention relates to the technical field of laser welding of continuous production lines, in particular to an intelligent laser welding system and method; the system comprises a laser welding machine which is connected through an industrial network for data interaction, a welding seam vision detection system and an intelligent welding control system, wherein the welding seam vision detection system comprises a vision sensor group, a controller and a welding seam quality detection system, the vision sensor group is used for collecting data before and after welding of a welding part and transmitting the data to the welding seam quality detection system through the controller, the welding seam quality detection system is used for checking whether a welding seam is qualified and transmitting the data to the intelligent welding control system, and the intelligent welding control system is used for adjusting and optimizing welding process parameters of laser welding. The welding system provided by the invention can quickly and accurately detect the quality of the welding seam, intelligently optimize welding process parameters according to the defects of the welding seam, improve the intelligent level of a laser welding machine and ensure that a production line can stably, safely and continuously run.)

1. An intelligent laser welding system, comprising:

the laser welding machine comprises a welding head, a welding head and a welding head, wherein the welding head is used for welding a workpiece and forming a welding seam;

the welding seam visual detection system comprises a visual sensor group, a controller and a welding seam quality detection system, wherein the visual sensor group is used for acquiring data of a welding part before and after welding and transmitting the data to the welding seam quality detection system through the controller, and the welding seam quality detection system is used for checking whether a welding seam is qualified or not;

the intelligent welding control system is used for adjusting the welding process parameters of the laser welding;

and the laser welding machine, the welding line visual detection system and the intelligent welding control system are connected through an industrial network to carry out data interaction.

2. The intelligent laser welding system of claim 1, wherein the set of vision sensors are disposed on both sides of the welding head in a welding direction, the set of vision sensors and the welding head being movable in the welding direction.

3. The intelligent laser welding system of claim 2, wherein the visual sensing group and the welding head are reset after welding is completed.

4. The intelligent laser welding system of claim 2, wherein the set of vision sensors comprises a first vision sensor disposed at the extending end of the welding direction for collecting data of a splicing gap of a workpiece before welding, and further comprises a second vision sensor and a third vision sensor disposed behind the welding direction for collecting data of an upper surface and a lower surface of a weld respectively.

5. The intelligent laser welding system of claim 1, wherein the intelligent welding control system comprises a welding process parameter acquisition module for acquiring process parameters of the laser welder and a weld process parameter intelligent adjustment module for receiving feedback from the weld quality detection system.

6. The intelligent laser welding system of claim 5, wherein the intelligent weld process parameter adjustment module can optimize and feed back weld process parameters to the laser welder.

7. An intelligent laser welding method is characterized by comprising the following steps:

s1: placing the workpiece in a laser welding machine, determining a welding position, and starting welding;

s2: in the welding process, a welding head and a visual sensor group move along the welding direction, the visual sensor group is used for acquiring data of a workpiece at the welding position before and after welding and transmitting the data to a welding seam quality detection system in real time through a controller, and the welding seam quality detection system is used for judging whether a welding seam is qualified or not; meanwhile, the intelligent welding control system collects real-time welding technological parameters of the laser welding machine;

s3: after welding, if the welding seam quality detection system detects that the welding seam is qualified, a qualified signal is fed back to the intelligent welding control system, and the laser welding machine is automatically turned on;

s4: and after welding, if the welding seam quality detection system detects that the welding seam is unqualified, feeding back defect information about the welding seam to the intelligent welding control system, intelligently optimizing welding process parameters according to the defect information fed back by the welding seam quality detection system and acquired real-time welding process parameters of the laser welding machine, feeding back the optimized welding process parameters to the laser welding machine, automatically starting re-welding by the laser welding machine, cutting off the defective welding seam, splicing the workpiece again, and re-welding according to the optimized welding process parameters until the welding seam quality detection system detects that the welding seam is qualified.

8. The intelligent laser welding method of claim 7, wherein in step S1, the laser welder further comprises centering, shearing, and splicing the workpiece.

9. The smart laser welding method as recited in claim 7, wherein in step S2, the real-time welding process parameters of the laser welder include welding speed, laser power, defocus amount, preheating power and annealing power.

10. The smart laser welding method according to claim 7, wherein in step S4, the defect information of the weld includes misalignment, weld porosity, weld depression, and weld protrusion.

Technical Field

The invention relates to the technical field of laser welding of continuous production lines, in particular to an intelligent laser welding system and method.

Background

The laser welder is an important device of a steel cold rolling continuous production line, is used for welding workpieces, is particularly commonly used in the production of plate strips, and is used for welding the tail parts and the head parts of front and rear steel coils to realize the continuous production of strip steel. In the operation process of the laser welding machine, factors such as equipment function precision, raw material defects, welding process parameters and the like can cause welding defects, even cause welding line fracture and cause production interruption.

At present, two methods are available for the quality inspection and release of laser welding seams in the steel industry: one method is to manually check the quality of a welding seam and adjust welding parameters according to welding defects, because the judgment standard of the quality of the welding seam is not unique manually and the levels of operators are uneven, the adjustment of welding process parameters is easy to be wrong, and once a bad welding seam enters the next process, production accidents such as the fracture of the welding seam and the like can be caused; the other method is to adopt welding seam quality inspection equipment to inspect the welding seam and inform an operator whether the welding seam is qualified or not, and an unqualified welding seam still needs to manually judge the defect type and manually adjust welding parameters for re-welding. At present laser welding in-process needs operating personnel to carry out the detection of welding seam quality, and consuming time and power, and judge that the standard is difficult to unify for welding efficiency is not high, also can influence off-the-shelf welding seam quality.

Disclosure of Invention

In order to solve the above problem, in one aspect, the present invention provides an intelligent laser welding system, which mainly includes:

the laser welding machine comprises a welding head, a welding head and a welding head, wherein the welding head is used for welding a workpiece and forming a welding seam;

the welding seam visual detection system comprises a visual sensor group, a controller and a welding seam quality detection system, wherein the visual sensor group is used for acquiring data of a welding part before and after welding and transmitting the data to the welding seam quality detection system through the controller, and the welding seam quality detection system is used for checking whether a welding seam is qualified or not;

the intelligent welding control system is used for adjusting the welding process parameters of the laser welding;

and the laser welding machine, the welding line visual detection system and the intelligent welding control system are connected through an industrial network to carry out data interaction.

Preferably, the group of vision sensors is disposed on both sides of the welding head in a welding direction, and the group of vision sensors and the welding head are movable in the welding direction.

Preferably, the visual sensing group and the welding head are reset after welding is completed.

Preferably, the visual sensor group comprises a first visual sensor arranged at the extending end in the welding direction and used for collecting data of a splicing gap of a workpiece before welding, and a second visual sensor and a third sensor which are arranged behind the welding direction and used for collecting data of the upper surface and the lower surface of a welding seam respectively.

Preferably, the intelligent welding control system comprises a welding process parameter acquisition module and a welding seam process parameter intelligent adjustment module, wherein the welding process parameter acquisition module is used for acquiring process parameters of the laser welding machine, and the welding seam process parameter intelligent adjustment module is used for receiving feedback of the welding seam quality detection system.

Preferably, the intelligent welding process parameter adjusting module can optimize welding process parameters and feed back the welding process parameters to the laser welding machine.

On the other hand, the invention provides an intelligent laser welding method, which comprises the following steps:

s1: placing the workpiece in a laser welding machine, determining a welding position, and starting welding;

s2: in the welding process, a welding head and a visual sensor group move along the welding direction, the visual sensor group is used for acquiring data of a workpiece at the welding position before and after welding and transmitting the data to a welding seam quality detection system in real time through a controller, and the welding seam quality detection system is used for judging whether a welding seam is qualified or not; meanwhile, the intelligent welding control system collects real-time welding technological parameters of the laser welding machine;

s3: after welding, if the welding seam quality detection system detects that the welding seam is qualified, a qualified signal is fed back to the intelligent welding control system, and the laser welding machine is automatically turned on;

s4: and after the step S2 is completed, if the welding seam quality detection system detects that the welding seam is unqualified, feeding back defect information about the welding seam to the intelligent welding control system, intelligently optimizing welding process parameters according to the defect information fed back by the welding seam quality detection system and acquired real-time welding process parameters of the laser welding machine by the intelligent welding control system, feeding back the optimized welding process parameters to the laser welding machine, automatically starting re-welding by the laser welding machine, cutting off the defective welding seam, splicing the workpieces again and re-welding according to the optimized welding process parameters until the welding seam quality detection system detects that the welding seam is qualified.

Preferably, in step S1, the laser welder further includes centering, cutting and splicing the workpiece.

Preferably, in step S2, the real-time welding process parameters of the laser welder include welding speed, laser power, defocus amount, preheating power and annealing power.

Preferably, in step S4, the defect information of the weld includes misalignment, weld porosity, weld recess, and weld protrusion.

The invention provides an intelligent laser welding system and a method, wherein the working principle is that a workpiece is placed in a laser welding machine for welding, in the welding process, a visual sensor group moves along a to-be-welded part of the workpiece along with a welding head and performs welding, the visual sensor group collects data of the welded part of the workpiece before and after welding and transmits the data to a welding seam quality detection system through a controller, the welding seam quality detection system is used for judging whether a welding seam is qualified or not through the processing of visual images and the identification of welding seam defects, and in the welding process, the intelligent welding control system also collects real-time welding process parameters of the laser welding machine; after welding is completed, the welding head and the visual sensor group are reset and prepared for the next welding process, if the welding seam quality detection system detects that the welding seam is qualified, a qualified signal is fed back to the intelligent welding control system, the laser welding machine is automatically opened, the next welding process can be carried out, continuous welding is realized, if the welding seam quality detection system detects that the welding seam is unqualified, the weld seam defect quantification is fed back to the intelligent welding control system through the controller, the intelligent welding seam process parameter adjustment module optimizes welding process parameters by adopting a neural network algorithm according to the fed-back welding seam defect information and in combination with real-time welding process parameters collected from the laser welding machine, and the optimized welding process parameters are fed back to the laser welding machine and guide the laser welding machine to weld qualified welding seams during re-welding.

The intelligent laser welding system can be used for welding various workpieces, is particularly suitable for welding plate strips, and realizes the continuous production of strip steel; the intelligent laser welding system is suitable for various laser welding processes such as laser welding, laser filler wire welding, laser arc hybrid welding and the like.

Due to the adoption of the technical scheme, compared with the prior art, the invention has the following beneficial effects:

1) the intelligent laser welding system provided by the invention improves the intelligent level of workpiece laser welding, adopts the visual sensor group to collect images and data, and transmits the images and data to the welding seam quality detection system for identification, so that a uniform judgment standard can be formed for the welding seam quality, the defects caused by manual judgment are avoided, and the welding seam quality is improved;

2) the intelligent laser welding system provided by the invention has the advantages that the dependence of the laser welding machine on operators is effectively reduced, the close-range operation of the operators can also be reduced, and the influence of the laser welding machine on the personal safety of the operators is avoided;

3) the intelligent laser welding system and the method provided by the invention can quickly, reliably and accurately detect the quality of the welding seam, intelligently optimize the technological parameters of the welding machine according to the detected defects of the welding seam, improve the intelligent level of the laser welding machine and ensure the stable, safe and continuous operation of a production line.

Drawings

Fig. 1 is a schematic structural diagram of an intelligent laser welding system according to the present invention.

1-laser welding machine; 101-a welding head; 2-a weld visual inspection system; 201-group of visual sensors; 2011-first vision sensor; 2012-a second vision sensor; 2013-a third vision sensor; 202-a controller; 203-weld quality detection system; 3-an intelligent welding control system; 4-the workpiece.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments, and all other embodiments obtained by a person of ordinary skill in the art without creative efforts based on the embodiments of the present invention belong to the protection scope of the present invention. In the drawings, the size and relative sizes of certain features may be exaggerated for clarity.

In the description of the present invention, unless expressly stated or limited otherwise, the terms "connected" and "coupled" are to be construed broadly, e.g., as meaning a fixed connection, a removable connection, or an integral part; can be mechanically or electrically connected; the term "connecting" may refer to a direct connection, an indirect connection through an intermediate, a connection between two elements or an interaction relationship between two elements, and a person skilled in the art can understand the specific meaning of the above terms in the present invention in a specific case.

In the description of the present invention, the terms "upper", "lower", "left", "right", "front", "rear", and the like are used in the orientations and positional relationships shown in the drawings only for convenience of description and simplicity of operation, and do not indicate or imply that the designated device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention.

As shown in the attached figure 1 of the specification, the invention provides an intelligent laser welding system which mainly comprises a laser welding machine 1, a weld visual detection system 2 and an intelligent welding control system 3, wherein the three systems are connected through an industrial network to carry out data interaction, so that the intelligent laser welding system can be formed; the laser welding machine 1 comprises a welding head 101 and is used for welding a workpiece 4 and forming a welding seam, the laser welding machine can adopt welding processes such as laser welding, laser filler wire welding and laser composite welding, the laser welding machine 1 can also carry out other processing on the workpiece, the processing comprises centering, shearing and splicing processing on two workpieces 4 to be welded, the workpiece 4 is enabled to be in a proper welding position, then the welding head carries out welding, a welding seam vision detection system carries out data acquisition on a splicing gap before welding of the welding position of the workpiece 4 and the welding seam after welding, and the image is processed and the defect of the welding seam is identified by acquiring the image, so that whether the welding seam has a defect or not is judged.

Further, the weld visual inspection system 2 comprises a visual sensor group 201, a controller 202 and a weld quality inspection system 203, the visual sensor group 201 transmits acquired visual images and data of a welded part before and after welding to the weld quality inspection system 203 through the controller 202 for inspecting whether the weld is qualified, the weld quality inspection system 203 feeds back the information of whether the weld is qualified or not at the analysis position to the intelligent welding control system 3, the weld quality inspection system 203 processes the visual images and analyzes whether the weld has weld defects, the defect information of the weld comprises visible defect curves and overproof values, and if the weld defects exist, the defect quantification is fed back to the intelligent welding control system 3 through the controller; in the welding process, the welding head 101 and the visual sensor group 201 can move along the welding direction, after one welding process is completed, the welding head 101 and the visual sensor group 201 reset and prepare for the next welding process, in the welding process, the welding head 101 and the visual sensor group 201 can be installed together, and during welding, the welding head 101 and the visual sensor group 201 can move together or can be installed separately, and in the moving process, the speed is kept consistent, so that the visual sensor group 201 can simultaneously acquire data of workpieces before and after welding.

The intelligent welding control system 3 comprises a welding process parameter acquisition module and a welding seam process parameter intelligent adjustment module, and is used for adjusting and optimizing the welding process parameters of the laser welding machine 1, in the welding process, the welding process parameter acquisition module is used for acquiring the process parameters of the laser welding machine 1, acquiring and recording data in real time, the welding process parameters comprise welding speed, laser power, defocusing amount, preheating power, annealing power and the like, the welding seam process parameter intelligent adjustment module is used for receiving the feedback of the welding seam quality detection system 203, establishing signal connection with the laser welding machine 1, and adjusting and controlling the laser welding machine 1, when the received signal is that the welding seam is qualified, the welding process parameters of the laser welding machine 1 are not required to be modified, the laser welding machine 1 is automatically opened, the next welding process can be carried out, and the continuous welding of the workpiece 4 can be realized, the welding device is particularly suitable for welding of the plate strip, and is used for welding the tail of the previous steel coil and the head of the next steel coil and realizing continuous welding operation; when the welding seam process parameter intelligent adjustment module receives a signal that the welding seam is unqualified, the welding seam process parameter intelligent adjustment module optimizes the welding process parameter by adopting a neural network algorithm according to the welding seam defect type fed back by the welding seam quality detection system 203 and by combining the real-time welding process parameter collected from the laser welding machine 1, feeds the optimized welding process parameter back to the laser welding machine 1, and then guides the laser welding machine 1 to cut, splice and re-weld the defective welding seam until the welding seam is qualified.

Further, the vision sensor group 201 comprises a first vision sensor 2011 arranged at the extending end of the welding direction and used for collecting data of the splicing gap of the workpieces 4 before welding, and further comprises a second vision sensor 2012 and a third vision sensor 2013 which are arranged behind the welding direction and used for collecting data of the upper surface and the lower surface of the welding seam respectively, the first vision sensor 2011 can monitor the splicing gap between the workpieces 4 before welding and provide basis for optimizing welding process parameters in the later period, and the second vision sensor 2012 and the third vision sensor 2013 can monitor the upper surface and the lower surface of the welding seam after welding and provide basis for optimizing the welding process parameters in the later period.

How to optimize the welding process parameters of the laser welding after the intelligent welding control system 3 receives the weld defect information fed back by the weld quality detection system 203 will be described in detail below.

If the laser welding machine of the adopted laser welding process is adopted in the intelligent laser welding system:

if the misalignment is a defect, the intelligent welding control system 3 adjusts the height of the welding head supporting wheel according to the misalignment s fed back by the welding seam quality detection system 203 and the collected real-time welding process parameters of the laser welding machine 1 and the height value of the welding head supporting wheel, wherein the numerical value is half of the misalignment, namely the numerical value is s/2;

if the weld seam is a weld seam sinking defect, the weld seam quality detection system 203 feeds back the percentage of the weld seam sinking value exceeding a standard value, the intelligent welding control system 3 reduces the welding speed value in the welding process parameters according to the fed-back exceeding percentage, reduces the welding speed in direct proportion to the exceeding percentage, and can adjust the welding speed to optimize the weld seam sinking defect;

if the weld joint is in the convex defect, the weld joint quality detection system 203 feeds back the percentage of the weld joint residual height value exceeding the standard value, the intelligent welding control system 3 improves the welding speed value in the welding process parameters according to the fed-back exceeding percentage, the welding speed is improved in direct proportion to the exceeding percentage, and the welding speed can be adjusted to optimize the convex defect of the weld joint;

if the weld seam is the air hole defect, the weld seam quality detection system 203 feeds back the density of the air hole defect, and the intelligent welding control system 3 reduces the welding speed and the welding power according to the fed back density of the air hole defect;

during the welding process, a single defect or a plurality of defects can appear together, and the intelligent welding control system 3 optimizes corresponding welding process parameters according to the defect types.

If the intelligent laser welding system adopts a laser filler wire welding or laser composite welding process:

if the misalignment is a defect, the intelligent welding control system 3 adjusts the height of the welding head supporting wheel according to the misalignment s fed back by the welding seam quality monitoring system 203 and the collected real-time welding process parameters of the laser welding machine 1 and the height value of the welding head supporting wheel, wherein the numerical value is half of the misalignment, namely the numerical value is s/2;

if the weld seam is a weld seam dent defect, the weld seam quality monitoring system 203 feeds back the percentage of the weld seam dent value exceeding the standard value, the intelligent welding control system 3 improves the wire feeding speed in the welding process parameters according to the exceeding percentage, and the wire feeding speed is improved in direct proportion to the exceeding percentage;

if the weld joint is in a convex defect, the weld joint quality monitoring system 203 feeds back the percentage of the weld joint residual height value exceeding a standard value, the intelligent welding control system 3 reduces the wire feeding speed value in the welding parameters according to the exceeding percentage, and the reduction of the wire feeding speed is in direct proportion to the exceeding percentage.

If the weld is the air hole defect, the weld quality monitoring system 203 feeds back the density of the air hole defect, and the intelligent welding control system 3 reduces the welding speed and the welding power according to the fed back density of the air hole defect.

During the welding process, a single defect or a plurality of defects can appear together, and the intelligent welding control system 3 optimizes corresponding welding process parameters according to the defect types.

Based on the intelligent laser welding system, the invention also provides an intelligent laser welding method, which comprises the following steps:

s1: placing the workpiece 4 in the laser welding machine 1, determining a welding position, and starting welding;

s2: in the welding process, the welding head 101 and the visual sensor group 201 move along the welding direction, the visual sensor group 201 is used for acquiring data of the workpiece 4 at the welding position before and after welding and transmitting the data to the welding seam quality detection system 203 through the controller 202 in real time, and the welding seam quality detection system 203 is used for judging whether the welding seam is qualified or not; meanwhile, the intelligent welding control system 3 collects real-time welding technological parameters of the laser welding machine 1;

s3: after welding, if the welding seam quality detection system 203 detects that the welding seam is qualified, a qualified signal is fed back to the intelligent welding control system 3, the laser welding machine 1 is automatically turned on, and the next welding process can be started;

s4: after welding, if the welding seam quality detection system 203 detects that the welding seam is unqualified, feeding back the defect information of the intelligent welding control system 3 about the welding seam, intelligently optimizing welding process parameters by the intelligent welding control system 3 according to the defect information fed back by the welding seam quality detection system 203 and acquired real-time welding process parameters of the laser welding machine 1, feeding back the optimized welding process parameters to the laser welding machine 1, automatically starting re-welding by the laser welding machine 1, cutting off the defective welding seam, re-splicing the workpieces, re-welding according to the optimized welding process parameters until the welding seam quality detection system 203 detects that the welding seam is qualified, and starting the next welding process.

Further, in step S1, the laser welder 1 further includes centering, cutting and splicing the workpiece 4.

Further, in step S2, the real-time welding process parameters of the laser welder 1 include welding speed, laser power, defocus amount, preheating power and annealing power; in step S4, the defect information of the weld includes misalignment, weld porosity, weld indentation, weld protrusion, and the like.

Further, after the completion of one welding in step S2, the welding head 101 and the visual sensor group 201 are reset and the next welding process is performed.

In summary, the present invention provides an intelligent laser welding machine system and method, which can rapidly, reliably and accurately detect the quality of the welding seam and intelligently optimize the welding process parameters according to the defects of the welding seam, thereby improving the intelligent level of the laser welding machine and ensuring the stable, safe and continuous operation of the production line.

It should be understood by those skilled in the art that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. Although an embodiment of the present invention has been described, it is to be understood that the present invention should not be limited to this embodiment, and variations and modifications can be made by those skilled in the art within the spirit and scope of the present invention as defined in the appended claims.