CN112705832B - Welding control method and welding system - Google Patents
Welding control method and welding system Download PDFInfo
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- CN112705832B CN112705832B CN202011476253.8A CN202011476253A CN112705832B CN 112705832 B CN112705832 B CN 112705832B CN 202011476253 A CN202011476253 A CN 202011476253A CN 112705832 B CN112705832 B CN 112705832B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/26—Auxiliary equipment
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Abstract
The embodiment of the invention discloses a welding control method and a welding system. The welding control method comprises the following steps: detecting the operation state of the welding machine; if the welding machine is in a welding state and operates in an energy mode, acquiring a first power sampling signal of the welding machine; acquiring the count value of the timer, and resetting the timer after the count value is acquired so as to control the timer to count again, wherein the count value is used as the welding time length of the welding machine in the last welding stage; acquiring a second power sampling signal for the welding machine; determining the energy increment generated by the welding machine in the last welding stage based on the first power sampling signal, the second power sampling signal and the welding duration; controlling an operating state of the welder based on the energy increment. The controller can automatically calculate the accumulated welding energy in the welding process according to the acquired parameters without a process of stopping and waiting, so that the welding process is uninterruptedly performed while the program structure is simplified, and the welding efficiency of the whole welding system is improved.
Description
Technical Field
The embodiment of the invention relates to a welding technology, in particular to a welding control method and a welding system.
Background
The ultrasonic welding system for the battery tabs mainly comprises four subsystems, namely an ultrasonic generator, a PLC (programmable logic controller) electric control module, a welding machine frame and a human-machine interaction interface (HMI). The PLC electric control module controls the welding energy of the welding system according to the power analog quantity and the operation control signal provided by the ultrasonic generator.
The power analog quantity of the ultrasonic generator is sampled to calculate the corresponding energy value when the energy control is realized. Currently, sampling is usually performed at fixed time intervals, and specifically, sampling is performed by timer interrupt or performing timed polling in a PLC. But the sequential programming mode can be interrupted by timed interruption, and the programming structure is more complicated and the programming difficulty is higher; the timed polling mode, although ensuring the sequential programming mode, always has a certain time interval between each polling, and the PLC is idle in this time interval, which is not favorable for faster data acquisition and control.
Disclosure of Invention
The embodiment of the invention provides a welding control method and a welding system, which are used for reducing the program structure of a controller in the welding system and improving the operation efficiency of the welding system.
In a first aspect, an embodiment of the present invention provides a welding control method, including:
detecting the operation state of the welding machine;
if the welding machine is in a welding state and operates in an energy mode, acquiring a first power sampling signal of the welding machine;
acquiring a count value of a timer, and clearing the timer after acquiring the count value to control the timer to count again, wherein the count value is used as the welding time length of the welding machine in the last welding stage;
acquiring a second power sampling signal for the welder;
determining an energy increment generated by the welder in the last welding stage based on the first power sampling signal, the second power sampling signal and the welding duration;
controlling an operating state of the welder based on the energy delta.
Optionally, before the detecting the operating state of the welder, the method further includes:
when a welding starting signal is detected, starting the timer to start timing;
acquiring an initial power signal of the welder in an initial welding stage, wherein the initial power signal is used for determining an energy increment generated by the welder in the initial welding stage;
and starting the welding machine to start welding.
Optionally, the controlling the operating state of the welder based on the energy increment includes:
determining a current accumulated weld energy based on the energy increment and historical weld energy;
comparing the accumulated welding energy with a preset welding energy set value;
if the accumulated welding energy is larger than or equal to the welding energy set value, controlling the welding machine to stop welding;
and if the accumulated welding energy is smaller than the set welding energy value, repeatedly executing the step of detecting the operation state of the welding machine, and controlling the operation state of the welding machine based on the detection result of the operation state of the welding machine.
Optionally, the repeatedly performing the step of detecting the operation state of the welder and controlling the operation state of the welder based on the detection result of the operation state of the welder includes:
detecting the operation state of the welding machine;
if the welder is in a welding state and operates in an energy mode, updating a count value of the timer and a first power sampling signal for the welder;
clearing the timer after updating the count value to control the timer to count again;
updating a second power sampling signal of the welder;
updating an energy increment generated by the welder based on the updated first power sampling signal, the updated timing value and the updated second power sampling signal;
controlling an operating state of the welder based on the updated energy delta.
Optionally, based on the first power sampling signal, the second power sampling signal and the welding duration, determining an energy increment generated by the welder in the last welding stage according to the following method:
ΔE＝(V1+V2)*0.5*A*T (1)
in the formula: delta E is the energy increment of the welding machine in the last welding stage, V1 is the first power sampling signal, V2 is the second power sampling signal, A is a preset power sampling signal-to-power coefficient, and T is the welding time length of the last welding stage.
Optionally, before the detecting the operating state of the welder, the method further includes:
initializing a power analog quantity ADC channel, wherein the power analog quantity ADC channel is used for sampling a power signal of the welding machine;
and acquiring a power conversion coefficient of the power sampling signal.
In a second aspect, embodiments of the present invention also provide a welding system, including at least a welder and a controller connected to the welder, the controller being configured to:
detecting the operation state of the welding machine;
if the welding machine is in a welding state and operates in an energy mode, acquiring a first power sampling signal of the welding machine;
acquiring a count value of a timer, and clearing the timer after acquiring the count value to control the timer to count again, wherein the count value is used as the welding time length of the welding machine in the last welding stage;
acquiring a second power sampling signal for the welder;
determining an energy increment generated by the welder in the last welding stage based on the first power sampling signal, the second power sampling signal and the welding duration;
controlling an operating state of the welder based on the energy delta.
Optionally, the controller is further configured to:
when a welding starting signal is detected, starting the timer to start timing;
acquiring an initial power signal of the welder in an initial welding stage, wherein the initial power signal is used for determining an energy increment generated by the welder in the initial welding stage;
and starting the welding machine to start welding.
Optionally, the controller is further configured to:
determining a current accumulated weld energy based on the energy increment and historical weld energy;
comparing the accumulated welding energy with a preset welding energy set value;
if the accumulated welding energy is larger than or equal to the welding energy set value, controlling the welding machine to stop welding;
and if the accumulated welding energy is smaller than the set welding energy value, repeatedly executing the step of detecting the operation state of the welding machine, and controlling the operation state of the welding machine based on the detection result of the operation state of the welding machine.
Optionally, the controller is a PLC controller, and the welding machine is an ultrasonic welding machine.
According to the welding control method provided by the embodiment of the invention, the controller detects the operation state of the welding machine, and when the welding machine is detected to be in operation and in an energy mode, the controller acquires the count value of the timer, wherein the count value is used as the welding time length of the last welding stage in the program execution process; the controller collects voltage digital quantities of power signals of the welding machine in a previous welding stage and a current welding stage through an analog quantity ADC channel, and then calculates welding energy increment generated by the welding machine in the previous welding stage according to the obtained voltage digital quantities of two adjacent power signals and welding time. The controller executes the same operation in each welding stage, so that in the process of executing the program sequence, the accumulated welding energy of the welding machine is automatically calculated by calculating the energy increment of each welding stage, and whether the accumulated welding energy reaches the target welding energy is judged, so that the motor is correspondingly controlled. In the embodiment, a non-timing polling mode and a non-equal-length sampling interval acquisition and calculation method are adopted, so that a sequential programming mode can be ensured, and the controller cannot be in an idle state at any time. The welding process is uninterruptedly performed while the program structure is simplified, and the welding efficiency of the whole welding system is improved.
Drawings
FIG. 1 is a flow chart of a welding control method according to an embodiment of the present invention;
FIG. 2 is a flow chart of another welding control method provided by an embodiment of the present invention;
FIG. 3 is a flow chart of yet another welding control method provided by an embodiment of the present invention;
fig. 4 is a block diagram of a welding system according to an embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not to be construed as limiting the invention. It should be further noted that, for the convenience of description, only some of the structures related to the present invention are shown in the drawings, not all of the structures.
The ultrasonic welding system for the battery tabs mainly comprises four subsystems, namely an ultrasonic generator, a PLC (programmable logic controller) electric control module, a welding machine frame and a human-machine interaction interface (HMI). The working mode of the battery tab ultrasonic welding system is mainly divided into a time mode and an energy mode, wherein the time mode takes a time set value with a fixed length as the input quantity of an ultrasonic generator to realize the welding function with the same time length; the energy mode is to use a fixed energy set value as the input quantity of the ultrasonic generator, and realize the welding function that the accumulated output energy of the system during single welding is equal to the set value.
The ultrasonic generators commonly available on the market generally have a man-machine interface installed on a panel for a user to set a set value of welding time length or welding energy, and also have an output port containing an operation control signal input and a power analog output signal. Only high-end ultrasound generators provide more communication interfaces such as RS232 and ethernet interfaces. After purchasing the ultrasonic generator, a user often needs to integrate the ultrasonic generator into the whole welding system, and as the welding system has more parameters to set, a special HMI interface is needed, so that the data input and output of the whole welding system can not be realized by using only the HMI of the ultrasonic generator. For cost reasons, this requires that the HMI and PLC electrical control module of the welding system can implement the energy control mode when the sonotrode is not providing a digital communication interface, and also only with the power analog and operational control signals provided by the sonotrode.
The key point for realizing the energy control is to quickly and accurately calculate the accumulated welding energy by using a PLC. And acquiring a power digital signal from the power analog quantity, and calculating a corresponding energy value in a corresponding time period in an integral mode. Sampling at fixed time intervals is the most common and traditional analog quantity sampling mode, and can be realized in a PLC (programmable logic controller) in a mode of regularly interrupting sampling by a timer or realizing regularly polling. But the interruption can interrupt the sequential programming mode, and the programming structure is more complicated and the programming difficulty is higher; the timed polling mode, although ensuring the sequential programming mode, always has a certain time interval between each polling, and the PLC is in idle state in this time interval, which is not favorable for faster data acquisition and control. Based on the above disadvantages, the embodiment of the present invention provides a novel method for calculating the accumulated welding energy of the welding machine by using non-equal sampling intervals in a non-timed polling manner. The method of the embodiment of the invention is further explained in the following with the attached drawings.
Fig. 1 is a flowchart of a welding control method according to an embodiment of the present invention, which is applicable to energy control of a welding machine, and the present embodiment cyclically samples output power of the welding machine in an irregular manner, and calculates accumulated welding energy of the welding machine according to the output power, so as to ensure that a sequential programming manner and a PLC are not in an idle state at any time. The method may be performed by a PLC controller, and with reference to fig. 1, the method comprises the steps of:
and S110, detecting the operation state of the welding machine.
Wherein the controller can detect the operating condition of the welder by querying the state values of the specified variables. For example, if the state value of the specified variable is 1, the controller determines that the welding machine is in a welding state; if the state value of the specified variable is 0, the controller determines that the welding machine does not weld currently.
Correspondingly, the program in the controller assigns a corresponding state value to the designated variable according to the detected corresponding trigger signal in the running process, so that the state value of the designated variable is matched with the real state of the welding machine.
And S120, if the welding machine is in a welding state and operates in an energy mode, acquiring a first power sampling signal of the welding machine.
From the above analysis, the welder can operate in a time mode and an energy mode. In this embodiment, when the controller detects that the welding machine is operating and is operating in the energy mode, the controller performs power sampling on the welding machine to acquire a first power sampling signal for the welding machine.
Specifically, the controller is connected with a power output port of the welding machine through an analog quantity ADC channel of the controller, so that the output power of the welding machine is subjected to AD sampling through the analog quantity ADC channel, and the voltage digital quantity of a power signal of the welding machine is obtained, and the voltage digital quantity of the power signal is the first power sampling signal.
And S130, acquiring a count value of the timer, and clearing the timer after the count value is acquired so as to control the timer to count again, wherein the count value is used as the welding time length of the welding machine in the last welding stage.
Wherein, the counting value of the timer reflects the welding time of the welding machine in the last welding stage. It should be noted that the welding stages in this embodiment are automatically divided during the execution of the program. The program supports a conventional sequential programming architecture, with the program corresponding to one welding phase per cycle during the cycle operation. When the program is executed to a certain step, the program can clear the timer to finish timing the previous welding stage; and the timer restarts timing after being cleared, the program runs circularly, and when the program is executed to the step again, the program clears the timer again, so that each welding stage is automatically defined in the program running process. Therefore, the accumulated welding energy in the energy mode can be calculated without setting the timed interrupt in the interrupt mode or setting the polling timing interval by searching the longest single polling period in the timed polling mode. The program structure has the advantages of low requirement on hardware configuration of the controller, low system cost and simple program structure.
And S140, acquiring a second power sampling signal of the welding machine.
The second power sampling signal is a sampling signal obtained after the welding duration of the previous welding stage is obtained, and thus the second power sampling signal is a power sampling signal of the welding machine in the current welding stage.
Similar to the first power sampling signal, the second power sampling signal is obtained by sampling the output power of the welding machine through an analog quantity ADC channel of the controller, namely the second power sampling signal is the voltage digital quantity of the power signal of the welding machine at the current welding stage.
S150, determining the energy increment generated by the welding machine in the last welding stage based on the first power sampling signal, the second power sampling signal and the welding time length.
In the embodiment, the welding time of the welding machine in the last welding stage (corresponding to the last cycle of the program) is counted, the welding energy increment of the welding machine in the last welding stage is calculated according to the voltage digital quantity of the power signal in the last welding stage and the voltage digital quantity of the power signal in the current welding stage (corresponding to the current cycle of the program), and the energy increment of the welding machine is always automatically calculated when the program runs circularly.
And S160, controlling the operation state of the welding machine based on the energy increment.
During the process of program cyclic operation, after calculating the current welding energy increment, the program records the energy increment in a variable assignment mode in each welding stage, so that the program is cyclically executed, the welding energy is continuously accumulated, when each welding stage is finished, the program can calculate the current accumulated welding energy, and the accumulated welding energy is compared with the target welding energy to determine whether the target welding state is reached or not, thereby determining whether to continue welding or stop welding.
According to the welding control method provided by the embodiment of the invention, the controller detects the operation state of the welding machine, and when the welding machine is detected to be in operation and in an energy mode, the controller acquires the count value of the timer, wherein the count value is used as the welding time length of the last welding stage in the program execution process; the controller collects voltage digital quantities of power signals of the welding machine in a previous welding stage and a current welding stage through an analog quantity ADC channel, and then calculates welding energy increment generated by the welding machine in the previous welding stage according to the obtained voltage digital quantities of two adjacent power signals and welding time. The controller executes the same operation in each welding stage, so that the accumulated welding energy of the welding machine is automatically calculated by calculating the energy increment of each welding stage in the process of executing the program sequence, and whether the accumulated welding energy reaches the target welding energy is judged, so that the motor is correspondingly controlled. In the embodiment, a non-timing polling mode and a non-equal-length sampling interval acquisition and calculation method are adopted, so that a sequential programming mode can be ensured, and the controller cannot be in an idle state at any time. The welding process is uninterruptedly performed while the program structure is simplified, and the welding efficiency of the whole welding system is improved.
Optionally, on the basis of the above technical solution, before detecting the operation state of the welding machine, the welding control method further includes:
when a welding starting signal is detected, starting a timer to start timing;
acquiring an initial power signal of the welding machine in an initial welding stage, wherein the initial power signal is used for determining an energy increment generated by the welding machine in the initial welding stage;
and starting the welding machine to start welding.
Wherein the welding initiation signal is triggered by a user. For example, a user may output a weld initiation signal to the controller via an external switch (e.g., a foot pedal).
In the initial welding stage when the welding machine is just started, the controller sets the historical welding energy value of welding to zero, so that when the initial welding stage is finished, the energy increment generated by the welding machine in the initial welding stage is the accumulated welding energy of the initial welding stage, and the first accumulated welding energy in one welding cycle is obtained.
Optionally, on the basis of the above technical solution, before each welding, the controller needs to perform the following operations:
initializing a power analog quantity ADC channel, wherein the power analog quantity ADC channel is used for sampling a power signal of a welding machine;
and acquiring a power conversion coefficient of the power sampling signal.
The analog quantity ADC channel is connected with a power signal output port of the welding machine so as to sample a power signal of the welding machine through the analog quantity ADC channel. It can be seen that the controller obtains the voltage digital quantity signal, so that the controller needs to convert the voltage digital quantity signal into a corresponding power signal when the energy increment of the welding machine is determined subsequently.
The power sampling signal to power coefficient is set by the user based on empirical values. The coefficient is used for converting the voltage digital quantity signal of the sampled power signal into a corresponding power signal in the subsequent step, so that the energy increment of the welding machine in each welding stage is calculated based on the converted power signal.
Optionally, fig. 2 is a flowchart of another welding control method provided in an embodiment of the present invention, where the embodiment is optimized based on the foregoing embodiment, and with reference to fig. 2, the method includes the following steps:
and S210, detecting the operation state of the welding machine.
S220, if the welding machine is in a welding state and operates in an energy mode, a first power sampling signal of the welding machine is obtained.
And S230, acquiring a count value of the timer, and clearing the timer after the count value is acquired to control the timer to count again, wherein the count value is used as the welding duration of the welding machine in the last welding stage.
And S240, acquiring a second power sampling signal of the welding machine.
And S250, determining the energy increment generated by the welding machine in the last welding stage based on the first power sampling signal, the second power sampling signal and the welding time length.
In one embodiment, the energy increment generated by the welder in the last welding stage can be determined by the following formula:
ΔE＝(V1+V2)*0.5*A*T (1)
in the formula: delta E is the energy increment of the welding machine in the last welding stage, V1 is a first power sampling signal, V2 is a second power sampling signal, A is a preset power sampling signal-to-power coefficient, and T is the welding time length of the last welding stage.
According to the embodiment, the controller samples the power signal output by the welding machine through the analog quantity ADC channel, so that the voltage digital quantity of the power signal is sampled by the controller, the voltage digital quantity of the power signal is multiplied by a preset coefficient to obtain a corresponding power signal, and the power signal is integrated to obtain the energy increment.
And S260, determining the current accumulated welding energy based on the energy increment and the historical welding energy.
The historical welding energy refers to the accumulated energy of the welder before the last welding stage. From the above analysis, the controller will record the accumulated welding energy at the end of each welding phase as the historical welding energy for the next welding phase. On this basis, the controller obtains an accumulated weld energy of the welder by adding the historical weld energy to the energy increment, the accumulated weld energy being indicative of a total weld energy produced by the welder up to a completed weld phase (a weld phase immediately preceding the current time).
And S270, comparing the accumulated welding energy with a preset welding energy set value.
Wherein, the preset welding energy set value is the target welding energy of the whole welding period. The controller obtains the accumulated weld energy for the entire weld cycle by accumulating the weld energy increments for each weld phase. It is apparent that by comparing the accumulated weld energy to the weld energy set point, it can be determined whether the weld task has been completed.
And S280, controlling the welding machine to stop welding if the accumulated welding energy is greater than or equal to the welding energy set value.
The controller compares the accumulated welding energy with a preset welding energy set value, and when the accumulated welding energy of the welding machine is greater than or equal to the preset welding energy set value, the controller indicates that the welding task of the current welding cycle is finished and the welding machine should stop welding.
And S290, if the accumulated welding energy is smaller than the welding energy set value, repeatedly executing the step of detecting the operation state of the welding machine, and controlling the operation state of the welding machine based on the detection result of the operation state of the welding machine.
If the accumulated welding energy is smaller than the set welding energy value, the welding task is not completed, the controller continues to acquire the operation state of the welding machine by executing a built-in program, and performs welding energy increment calculation in a corresponding state until the accumulated welding energy of the welding machine is detected to reach the set welding energy value.
In one embodiment, this step may be further optimized as:
detecting the operation state of the welding machine;
if the welder is in a welding state and operates in an energy mode, updating a count value of a timer and a first power sampling signal for the welder;
resetting the timer after updating the count value to control the timer to count again;
updating a second power sampling signal of the welding machine;
updating an energy increment generated by the welding machine based on the updated first power sampling signal, the updated timing value and the updated second power sampling signal;
controlling an operating state of the welder based on the updated energy increment.
In the process of executing the program in a circulating manner, after the count value of the timer is acquired each time, the controller controls the timer to be cleared, so that the timer starts to time the next welding stage.
It should be noted that, because the program is executed in a loop, the first power sampling signal, the second power sampling signal and the counting value are updated in real time, that is, each time a loop is executed, the first power signal, the second power signal and the counting value are updated once, the program is executed in a loop until the accumulated welding energy reaches the welding energy set value when the loop is executed, the loop is exited, and the controller controls the welding machine to stop the welding operation.
In the welding control method provided by this embodiment, after receiving an external welding start signal, the controller starts the welding machine to start welding operation, and at the same time, the controller performs zero setting processing on the welding energy in the initial welding stage to complete calculation of the accumulated welding energy in the initial welding stage, and starts the timer to start timing in the initial welding stage; when the program is executed to the corresponding cycle node, the controller reads the timing value of the timer to obtain the welding time length of the welding in the welding stage which is currently finished, the controller further performs zero clearing operation on the timer to enable the timer to time the welding stage to be started, the controller further obtains the power sampling signal of the welding stage which is currently finished and the power sampling signal of the welding stage to be started, the output power of the welding machine is calculated based on the two power sampling signals and a preset power coefficient, and the energy increment of the welding machine is calculated by combining the read welding time length. The controller repeatedly samples the output power of the welding machine to continuously update the accumulated welding energy generated by the welding machine by circularly executing a built-in program, compares the accumulated welding energy with a set welding energy set value, and controls the welding machine to stop welding when the accumulated welding energy is detected to reach the set welding energy set value, so that the welding operation is finished. Otherwise, the controller operates circularly through a built-in program, and the welding energy increment is automatically calculated in each cycle until the accumulated welding energy of the welding machine reaches the set welding energy value, and the welding operation is stopped. The embodiment can automatically calculate the energy increment of each cycle through the cyclic execution of the built-in program to obtain the accumulated welding energy of the welding machine, and detect whether the welding is finished or not by comparing the accumulated welding energy with the set welding energy value, thereby realizing the continuous operation of the controller while realizing the sequential programming and improving the operation efficiency of the controller.
Optionally, fig. 3 is a flowchart of another welding control method provided in an embodiment of the present invention, where the embodiment is optimized based on the foregoing embodiment, and referring to fig. 3, the method specifically includes the following steps:
and S310, starting.
And S320, initializing a power analog quantity ADC channel, and setting a voltage digital quantity to power conversion coefficient of the power signal.
And S330, initializing a 1ms timer.
The 1ms timer is a timer used in this embodiment, that is, in this embodiment, it is preferable that the 1ms timer counts each welding phase, and the controller obtains the welding time length of the corresponding welding phase by reading a count value of the 1ms timer. Of course, the timer can be selected according to the configuration of the controller, and when the controller configures a timer with higher accuracy, the timer with higher accuracy can be used to time each welding time length. The selection of the timer is not limited in this embodiment.
And S340, other initialization.
And S350, initializing other electric appliance control programs.
And S360, judging whether a welding starting signal is received or not.
If an external welding start signal is received, indicating that the welding cycle is started in the present cycle, entering step S370; otherwise, the process proceeds to step S380.
And S370, clearing the timer and starting to count again.
And S371, sampling the latest power signal voltage digital quantity.
And S372, setting the energy accumulation value to be zero.
At this time, because the welder just started welding and the welding energy has not been accumulated, the controller sets the energy accumulation value to zero at this time.
S380, whether the welding is welding and in an energy mode.
If yes, go to step S390; otherwise, returning to step S350, the above steps are repeated.
And S390, reading the timer.
The controller reads the count value of the timer and records the read count value into the variable T in a variable assignment mode.
And S400, clearing the timer and starting to count again.
The controller clears the timer in the step to define a previous welding stage and a next welding stage. And after the timer is cleared, the count value counted again by the timer is the welding time length of the next welding stage.
And S410, acquiring the voltage digital quantity of the power signal of the last welding stage and the voltage digital quantity of the power signal of the welding stage to be started.
And S420, calculating the accumulated welding energy.
Wherein the controller calculates the accumulated welding energy at the welding stage just finished by the following formula:
E＝Ehistory of+(V1+V2)*0.5*A*T (2)
In the formula: e is the cumulative welding energy, EHistory ofFor historical welding energy, Δ E is the energy increment of the welding machine in the last welding stage, V1 is the first power sampling signal, V2 is the second power sampling signal, a is the preset power sampling signal-to-power coefficient, and T is the welding duration of the last welding stage.
And S430, judging whether the accumulated welding energy reaches a set welding energy set value.
If yes, indicating that the accumulated output energy of the welding machine reaches the required energy, and entering step S440; if not, the welding is not completed, the step S350 is returned, and the steps are repeatedly executed.
And S440, outputting a welding stopping command.
S450, setting a final welding energy value.
At the moment, the welding is finished, and the controller records the accumulated welding energy obtained at the moment in a variable assignment mode so as to obtain the final welding energy of the welding machine.
And S460, ending.
Alternatively, fig. 4 is a block diagram of a welding system according to an embodiment of the present invention, and referring to fig. 4, the welding system 40 at least includes a welder 41 and a controller 42 connected to the welder 41, wherein,
the controller 42 is configured to:
detecting an operation state of the welder 41;
if the welder 41 is in a welding state and operating in an energy mode, acquiring a first power sampling signal for the welder 41;
acquiring a count value of the timer, and resetting the timer after acquiring the count value to control the timer to count again, wherein the count value is used as the welding duration of the welding machine 41 in the last welding stage;
acquiring a second power sampling signal for the welder 41;
determining the energy increment generated by the welding machine 41 in the last welding stage based on the first power sampling signal, the second power sampling signal and the welding time length;
the operating state of the welder 41 is controlled based on the energy increment.
Optionally, on the basis of the above technical solution, the controller 42 is further configured to perform the following operations before detecting the operation state of the welder 41:
when a welding starting signal is detected, starting a timer to start timing;
acquiring an initial power signal of the welder 41 in an initial welding stage, wherein the initial power signal is used for determining an energy increment generated by the welder 41 in the initial welding stage;
the welder 41 is activated to start welding.
Optionally, on the basis of the above technical solution, the controller 42 is further specifically configured to:
determining a current accumulated weld energy based on the energy increment and the historical weld energy;
comparing the accumulated welding energy with a preset welding energy set value;
if the accumulated welding energy is greater than or equal to the welding energy set value, controlling the welding machine 41 to stop welding;
if the accumulated welding energy is less than the welding energy set value, the step of detecting the operation state of the welder 41 is repeatedly performed, and the operation state of the welder 41 is controlled based on the detection result of the operation state of the welder 41.
Optionally, on the basis of the above technical solution, the controller 42 is further specifically configured to:
detecting an operation state of the welder 41;
if the welder 41 is in a welding state and operating in the energy mode, updating a count value of the timer and a first power sample signal for the welder 41;
resetting the timer after updating the count value to control the timer to count again;
updating the second power sampling signal of the welder 41;
updating the energy increment generated by the welder 41 based on the updated first power sampling signal, the updated timing value, and the updated second power sampling signal;
the operating state of the welder 41 is controlled based on the updated energy increment.
Optionally, on the basis of the above technical solution, the controller 42 is further specifically configured to: based on the first power sampling signal, the second power sampling signal and the welding duration, the energy increment generated by the welder 41 in the last welding stage is determined as follows:
ΔE＝(V1+V2)*0.5*A*T (1)
in the formula: Δ E is the energy increment of the welding machine 41 in the previous welding stage, V1 is the first power sampling signal, V2 is the second power sampling signal, a is the preset power sampling signal-to-power coefficient, and T is the welding duration of the previous welding stage.
Optionally, on the basis of the above technical solution, the controller 42 is further specifically configured to perform the following operations before detecting the operation state of the welder 41:
initializing a power analog quantity ADC channel, wherein the power analog quantity ADC channel is used for sampling a power signal of the welder 41;
and acquiring a power conversion coefficient of the power sampling signal.
Optionally, on the basis of the above technical solution, the controller 42 is a PLC controller, and the welding machine 41 is an ultrasonic welding machine.
It is to be noted that the foregoing is only illustrative of the preferred embodiments of the present invention and the technical principles employed. It will be understood by those skilled in the art that the present invention is not limited to the particular embodiments described herein, but is capable of various obvious changes, rearrangements and substitutions as will now become apparent to those skilled in the art without departing from the scope of the invention. Therefore, although the present invention has been described in greater detail by the above embodiments, the present invention is not limited to the above embodiments, and may include other equivalent embodiments without departing from the spirit of the present invention, and the scope of the present invention is determined by the scope of the appended claims.
Claims (9)
1. A welding control method, comprising:
detecting the operation state of the welding machine;
if the welding machine is in a welding state and operates in an energy mode, acquiring a first power sampling signal of the welding machine;
acquiring a count value of a timer, and clearing the timer after acquiring the count value to control the timer to count again, wherein the count value is used as the welding time length of the welding machine in the last welding stage;
acquiring a second power sampling signal for the welder;
determining an energy increment generated by the welder in the last welding stage based on the first power sampling signal, the second power sampling signal and the welding duration;
the energy is continuously accumulated to obtain a current accumulated welding energy at the end of each welding phase, and the accumulated welding energy is compared with a target welding energy to determine whether a target welding state has been reached;
wherein the energy increment generated by the welder in the last welding stage is determined according to the following method:
ΔE＝(V1+V2)*0.5*A*T
in the formula: delta E is the energy increment of the welding machine in the last welding stage, V1 is the first power sampling signal, V2 is the second power sampling signal, A is a preset power sampling signal-to-power coefficient, and T is the welding time length of the last welding stage.
2. The weld control method according to claim 1, wherein prior to the detecting an operational state of the welder, the method further comprises:
when a welding starting signal is detected, starting the timer to start timing;
acquiring an initial power signal of the welder in an initial welding stage, wherein the initial power signal is used for determining an energy increment generated by the welder in the initial welding stage;
and starting the welding machine to start welding.
3. The weld control method of claim 1, wherein the controlling the operating state of the welder based on the energy delta comprises:
determining a current accumulated weld energy based on the energy increment and historical weld energy;
comparing the accumulated welding energy with a preset welding energy set value;
if the accumulated welding energy is larger than or equal to the welding energy set value, controlling the welding machine to stop welding;
and if the accumulated welding energy is less than the welding energy set value, repeatedly executing the step of detecting the operation state of the welding machine, and controlling the operation state of the welding machine based on the detection result of the operation state of the welding machine.
4. The welding control method according to claim 3, wherein the repeatedly performing the step of detecting the operating state of the welder and controlling the operating state of the welder based on the detection result of the operating state of the welder includes:
detecting the operation state of the welding machine;
if the welder is in a welding state and operates in an energy mode, updating a count value of the timer and a first power sampling signal for the welder;
clearing the timer after updating the count value to control the timer to count again;
updating a second power sampling signal of the welder;
updating an energy increment generated by the welder based on the updated first power sampling signal, the updated timing value and the updated second power sampling signal;
controlling an operating state of the welder based on the updated energy delta.
5. The weld control method according to claim 1, wherein prior to the detecting an operating condition of the welder, the method further comprises:
initializing a power analog quantity ADC channel, wherein the power analog quantity ADC channel is used for sampling a power signal of the welding machine;
and acquiring a power conversion coefficient of the power sampling signal.
6. A welding system, comprising at least a welder and a controller coupled to the welder, the controller configured to:
detecting the operating state of the welding machine;
if the welding machine is in a welding state and operates in an energy mode, acquiring a first power sampling signal of the welding machine;
acquiring a count value of a timer, and clearing the timer after the count value is acquired so as to control the timer to count again, wherein the count value is used as the welding duration of the welding machine in the last welding stage;
acquiring a second power sampling signal for the welder;
determining an energy increment generated by the welder in the last welding stage based on the first power sampling signal, the second power sampling signal and the welding duration;
the energy is continuously accumulated to obtain a current accumulated welding energy at the end of each welding phase, and the accumulated welding energy is compared with a target welding energy to determine whether a target welding state has been reached;
determining the energy increment generated by the welder in the last welding stage according to the following method:
ΔE＝(V1+V2)*0.5*A*T
in the formula: delta E is the energy increment of the welding machine in the last welding stage, V1 is the first power sampling signal, V2 is the second power sampling signal, A is a preset power sampling signal-to-power coefficient, and T is the welding time length of the last welding stage.
7. The welding system of claim 6, wherein the controller is further configured to:
when a welding starting signal is detected, starting the timer to start timing;
acquiring an initial power signal of the welder in an initial welding stage, wherein the initial power signal is used for determining an energy increment generated by the welder in the initial welding stage;
and starting the welding machine to weld.
8. The welding system of claim 6, wherein the controller is further configured to:
determining a current accumulated weld energy based on the energy increment and historical weld energy;
comparing the accumulated welding energy with a preset welding energy set value;
if the accumulated welding energy is larger than or equal to the welding energy set value, controlling the welding machine to stop welding;
and if the accumulated welding energy is smaller than the set welding energy value, repeatedly executing the step of detecting the operation state of the welding machine, and controlling the operation state of the welding machine based on the detection result of the operation state of the welding machine.
9. The welding system of claim 6,
the controller is a PLC controller, and the welding machine is an ultrasonic welding machine.
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| CN102653029A (en) * | 2011-03-03 | 2012-09-05 | 通用汽车环球科技运作有限责任公司 | Multi-mode ultrasonic welding control and optimization |
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