CN117900621B - Welding quality real-time monitoring system based on beam splitting prism - Google Patents
Welding quality real-time monitoring system based on beam splitting prism Download PDFInfo
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- CN117900621B CN117900621B CN202410091303.2A CN202410091303A CN117900621B CN 117900621 B CN117900621 B CN 117900621B CN 202410091303 A CN202410091303 A CN 202410091303A CN 117900621 B CN117900621 B CN 117900621B
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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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
- B23K26/064—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
- B23K26/0652—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms comprising prisms
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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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/70—Auxiliary operations or equipment
- B23K26/702—Auxiliary equipment
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/01—Arrangements or apparatus for facilitating the optical investigation
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/01—Arrangements or apparatus for facilitating the optical investigation
- G01N2021/0106—General arrangement of respective parts
- G01N2021/0112—Apparatus in one mechanical, optical or electronic block
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Abstract
本发明公开了一种基于分光棱镜的焊接质量实时监测系统，涉及焊接监测技术领域，解决了目前的分光光路与监测光路结构复杂，镜片数量多，不利于机械结构设计与安装，且多镜片的光学系统对同轴度要求高的技术问题；包括分光棱镜，该分光棱镜将会回光分为三个不同的波段，以第二平面透镜和第三平面透镜对分光棱镜的反射的光进行聚焦至第一光电探测器和第二光电探测器，而穿过分光棱镜半透半反面S1和半透半反面S2的回反光透射至第三光电探测器，从而得到三组波段反射光并转化为电信号数据，再将对应的电信号数据进行对比分析以判断焊缝质量的好坏，该方式仅仅采用一块棱镜进行分光，极大程度的简化了现有焊接中监测光伏中复杂的分光系统。
The invention discloses a real-time monitoring system for welding quality based on a beam splitter prism, relates to the technical field of welding monitoring, solves the technical problems that the existing beam splitting optical path and monitoring optical path are complex in structure, the number of lenses is large, which is not conducive to mechanical structure design and installation, and the optical system of multiple lenses has high requirements for coaxiality; the invention comprises a beam splitter prism, which divides the return light into three different bands, focuses the reflected light of the beam splitter prism to a first photodetector and a second photodetector by a second plane lens and a third plane lens, and the return light passing through the semi-transparent semi-reflective surface S1 and the semi-transparent semi-reflective surface S2 of the beam splitter prism is transmitted to the third photodetector, thereby obtaining three groups of reflected light of the wave bands and converting them into electrical signal data, and then comparing and analyzing the corresponding electrical signal data to judge the quality of the weld. This method only uses one prism for beam splitting, which greatly simplifies the complex beam splitting system in the existing monitoring photovoltaic in welding.
Description
Technical Field
The invention belongs to the technical field of welding monitoring, and particularly relates to a welding quality real-time monitoring system based on a beam splitter prism.
Background
Laser welding is applied to welding of various materials. In addition, when large-particle splashing and large-size air holes are formed in the welding process, the quality or the attractiveness of the welding seam can be influenced. The welding quality monitoring is particularly important when poor welding quality, false welding and other welding quality are not up to standard easily, and urgent requirements are put forward for online detection of the welding seam quality along with continuous expansion of laser welding technology.
The optical system of current welding process real-time supervision light path is complicated, and beam split light path and monitoring light path structure are complicated, and lens quantity is many, is unfavorable for mechanical structure design and installation, and the optical system of many lenses is high to the axiality requirement. The mechanical structure design precision requirement can be greatly increased, and the mechanical structure processing difficulty is increased, so that serious potential safety hazards are caused for large-scale automatic welding production.
Disclosure of Invention
The present invention aims to solve at least one of the technical problems existing in the prior art; therefore, the invention provides a welding quality real-time monitoring system based on a beam splitting prism, which is used for solving the technical problems that the existing beam splitting optical path and monitoring optical path are complex in structure, the number of lenses is large, the mechanical structural design and installation are not facilitated, and the optical system with multiple lenses has high requirements on coaxiality.
To achieve the above object, a first aspect of the present invention provides a welding quality real-time monitoring system based on a beam splitter prism, including: the welding assembly and the information acquisition assembly are connected with the welding assembly;
the welding assembly comprises a welding workpiece and a welding vibrating mirror for controlling the direction of a welding light beam, a focusing lens is arranged at the bottom of the welding vibrating mirror and right above the welding workpiece, a first plano-convex lens for collimating the laser light beam is arranged above the welding vibrating mirror, and a laser welder is arranged in the vertical extension direction of the plane of the first plano-convex lens;
The information acquisition component is used for acquiring the retro-reflective electric signal data;
The information acquisition component comprises a beam splitting prism used for carrying out band separation on the reflection light generated in the welding process and a third photoelectric detector positioned on one side of the beam splitting prism and used for receiving transmission light, a second plano-convex lens and a third plano-convex lens used for focusing the reflection light are respectively arranged on the upper side and the lower side of the beam splitting prism, a first photoelectric detector and a second photoelectric detector used for receiving the reflection light are respectively arranged in the vertical extension direction of the plane of the second plano-convex lens and the plane of the third plano-convex lens, and the first photoelectric detector, the second photoelectric detector and the third photoelectric detector convert the received reflection light or transmission light into corresponding electric signal data.
The light-splitting prism is used for dividing the back light into three wave bands, and the received reflected light is converted into corresponding electric signal data through the first photoelectric detector, the second photoelectric detector and the third photoelectric detector, so that a complex light-splitting system in the existing welding monitoring photovoltaic is greatly simplified, and the mechanical design of monitoring equipment can be simplified.
Preferably, the beam splitter prism is a triangular prism, the cross section of the beam splitter prism is a right triangle, the surfaces extending from two right-angle sides of the beam splitter prism are respectively a semi-transparent semi-reverse surface S1 and a semi-transparent semi-reverse surface S2, and the surface extending from the hypotenuse of the beam splitter prism is an anti-reflection surface S3.
It should be noted that, this effect can be achieved by using prisms having other shapes in cross section, and the positions of the first photodetector, the second photodetector, and the third photodetector, and the corresponding second plano-convex lens and third plano-convex lens need to be adjusted at this time.
Preferably, the semi-transparent and semi-transparent surface S1 is used for reflecting the retro-reflection light of the wave band of 350nm-900nm, the semi-transparent and semi-transparent surface S2 is used for reflecting the retro-reflection light of the wave band of 1000nm-1100nm, and the anti-reflection surface S3 is used for transmitting the retro-reflection light of the wave band of 1200nm-2000 nm.
Preferably, a first optical filter with a transmission wave band of 350nm-900nm is arranged between the first photoelectric detector and the second plano-convex lens, a second optical filter with a transmission wave band of 1000nm-1100nm is arranged between the third plano-convex lens and the second photoelectric detector, and a third optical filter with a transmission wave band of 1200nm-2000nm is arranged between the beam splitting prism and the third photoelectric detector.
Preferably, the welding quality real-time monitoring system based on the beam splitter prism further comprises a data processing module connected with the information acquisition component;
The data processing module: corresponding electric signal data converted by the first photoelectric detector, the second photoelectric detector and the third photoelectric detector are obtained, and the corresponding electric signal data are compared with a preset range threshold value to obtain a comparison result; generating a prompt mark of the welding point based on the comparison result; the comparison result comprises a safety point, an early warning point and a minimum difference value corresponding to the early warning point, and the prompt mark comprises a safety mark and an early warning mark; and
And judging whether the welding quality meets the use standard or not based on the prompt mark.
Through marking three groups of electric signal data and corresponding range thresholds, welding seams with higher welding quality can be screened out, and welding quality meeting the use standard can be screened out through prompting marking.
Preferably, the comparing the corresponding electrical signal data with a preset range threshold value includes:
extracting corresponding electric signal data converted by the first photoelectric detector, the second photoelectric detector and the third photoelectric detector, and marking the corresponding electric signal data as XH1, XH2 and HX3 respectively;
Judging whether the electric signal data XH1 is in a preset low-frequency range threshold value [ M1, M2]; the electrical signal data XH1 is marked as a security point; if not, marking the electric signal data XH1 as an early warning point, calculating the minimum difference value between the electric signal data XH1 and the low-frequency range threshold value, and marking the minimum difference value as CZ1;
Judging whether the electric signal data XH2 is in a preset intermediate frequency range threshold value [ M3, M4]; the electrical signal data XH2 is marked as a security point; if not, marking the electric signal data XH2 as an early warning point, calculating the minimum difference value between the electric signal data XH2 and the low-frequency range threshold value, and marking the minimum difference value as CZ2;
judging whether the electric signal data XH3 is in a preset high-frequency range threshold value [ M5, M6]; the electrical signal data XH3 is marked as a security point; and if not, marking the electric signal data XH3 as an early warning point, calculating the minimum difference between the electric signal data XH3 and the low-frequency range threshold value, and marking the minimum difference as CZ3.
Preferably, the generating the indication mark of the welding point based on the comparison result includes:
Extracting a comparison result, and judging whether an early warning point exists in the comparison result; if not, generating a qualified mark; and generating a prompt mark according to the minimum difference value.
Preferably, the generating the prompt mark according to the minimum difference value includes:
extracting a minimum difference CZ corresponding to the early warning point, calculating a risk coefficient through a formula WX=alpha 1X CZ1+alpha 2X CZ2+alpha 3X CZ3, and comparing the risk coefficient WX with a preset risk threshold; if the risk coefficient WX is smaller than the risk threshold value, generating a qualified mark; otherwise, generating an early warning mark; wherein α1, α2, and α3 are preset scaling factors, and α1 > α2 > α3.
It should be noted that the risk threshold may be set by itself according to the usage requirement scenario of the weld.
Preferably, the determining whether the welding quality meets the use standard based on the prompt mark includes:
The numbers of the early warning marks and the qualified marks in the statistics prompt marks are marked as YJ and HG respectively, and the occupation ratio ZB is calculated through a formula ZB=YJ/HG; comparing the duty ratio ZB with a preset duty ratio threshold; if the duty ratio ZB is smaller than the duty ratio threshold, marking the welding quality as qualified welding; otherwise, the welding quality is marked as unqualified welding.
The quality of the whole welding seam can be reflected by calculating the duty ratio ZB, and the duty ratio threshold is set according to the use scene, so that the welding seam can be graded during processing, and the utilization rate of a welding finished product is further improved.
Compared with the prior art, the invention has the beneficial effects that:
1. The welding assembly comprises a beam splitting prism, the beam splitting prism splits return light into three different wave bands, the second plane lens and the third plane lens focus the reflected light of the beam splitting prism to the first photoelectric detector and the second photoelectric detector, the return light passing through the semi-transparent half-reverse surface S1 and the semi-transparent half-reverse surface S2 of the beam splitting prism is transmitted to the third photoelectric detector, so that three groups of wave band reflected light is obtained and converted into electric signal data, and the corresponding electric signal data is compared and analyzed to judge the quality of a welding line.
2. In the invention, the collected electric signal data is compared with the range threshold value preset by the corresponding wave band through the data processing module so as to preliminarily judge the welding quality of the welding line, a prompt mark is generated through the comparison result, and whether the welding quality accords with the use standard is further judged based on the number ratio of the early warning mark and the qualified mark in the prompt mark.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic illustration of the present invention;
FIG. 2 is a perspective view of a beam splitting prism according to the present invention;
FIG. 3 is a side view of a beam splitting prism of the present invention;
FIG. 4 is a schematic diagram of a data processing module according to the present invention.
In the figure, 1, a laser welder; 2. a first plano-convex lens; 3. welding a vibrating mirror; 4. a focusing lens; 5. welding a workpiece; 6. a first photodetector; 7. a second plano-convex lens; 8. a beam-splitting prism; 9. a third plano-convex lens; 10. a second photodetector; 11. a third photodetector; 12. a first optical filter; 13. a second optical filter; 14. and a third filter.
Detailed Description
The technical solutions of the present invention will be clearly and completely described in connection with the embodiments, and it is obvious that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1-4, an embodiment of a first aspect of the present invention provides a welding quality real-time monitoring system based on a beam splitter prism, including: the welding assembly and the information acquisition assembly are connected with the welding assembly;
The welding assembly comprises a welding workpiece 5 and a welding galvanometer 3 for controlling the direction of a welding light beam, wherein a focusing lens 4 is arranged at the bottom of the welding galvanometer 3 and right above the welding workpiece 5, a first plano-convex lens 2 for collimating a laser light beam is arranged above the welding galvanometer 3, and a laser welder 1 is arranged in the vertical extension direction of the plane of the first plano-convex lens 2;
The information acquisition component is used for acquiring the retro-reflective electric signal data;
The information acquisition component comprises a beam splitting prism 8 for carrying out band separation on the back reflection generated in the welding process and a third photoelectric detector 11 positioned on one side of the beam splitting prism 8 and used for receiving transmitted light, a second plano-convex lens 7 and a third plano-convex lens 9 for focusing the reflected light are respectively arranged on the upper side and the lower side of the beam splitting prism 8, a first photoelectric detector 6 and a second photoelectric detector 10 for receiving the reflected light are respectively arranged in the vertical extension directions of the planes of the second plano-convex lens 7 and the third plano-convex lens 9, and the first photoelectric detector 6, the second photoelectric detector 10 and the third photoelectric detector 11 convert the received reflected light or the transmitted light into corresponding electric signal data.
In order to enable the dichroic prism 8 to more uniformly separate the retro-reflection light into the wave bands, the dichroic prism 8 is a triangular prism, the cross section of the dichroic prism 8 is a right triangle, the faces extending from two right-angle sides of the dichroic prism 8 are respectively a semi-transparent semi-reverse face S1 and a semi-transparent semi-reverse face S2, and the face extending from the hypotenuse of the dichroic prism 8 is an anti-reflection face S3.
Further, the semi-transparent and semi-reflective surface S1 is used for reflecting the retro-reflection light of the wave band of 350nm-900nm, the semi-transparent and semi-reflective surface S2 is used for reflecting the retro-reflection light of the wave band of 1000nm-1100nm, and the anti-reflection surface S3 is used for transmitting the retro-reflection light of the wave band of 1200nm-2000 nm;
It should be noted that: coating films of different materials can be stuck on the surface of the beam splitting prism to realize the back reflection of the wave band of 350nm-900nm, the back reflection of the wave band of 1000nm-1100nm and the back reflection of the wave band of 1200nm-2000 nm.
Further, in order to avoid interference caused by external light, a first optical filter 12 for transmitting light with a wave band of 350nm-900nm is arranged between the first photoelectric detector 6 and the second plano-convex lens 7, a second optical filter 13 for transmitting light with a wave band of 1000nm-1100nm is arranged between the third plano-convex lens 9 and the second photoelectric detector 10, and a third optical filter 14 for transmitting light with a wave band of 1200nm-2000nm is arranged between the beam splitting prism 8 and the third photoelectric detector 11.
The welding quality real-time monitoring system based on the beam splitter prism further comprises a data processing module connected with the information acquisition component;
The data processing module: corresponding electric signal data converted by the first photoelectric detector 6, the second photoelectric detector 10 and the third photoelectric detector 11 are obtained, and the corresponding electric signal data are compared with a preset range threshold value to obtain a comparison result; generating a prompt mark of the welding point based on the comparison result; the comparison result comprises a safety point, an early warning point and a minimum difference value corresponding to the early warning point, and the prompt mark comprises a safety mark and an early warning mark; and
And judging whether the welding quality meets the use standard or not based on the prompt mark.
In this embodiment, comparing the corresponding electrical signal data with a preset range threshold includes:
Extracting corresponding electric signal data converted by the first photoelectric detector 6, the second photoelectric detector 10 and the third photoelectric detector 11, and marking the corresponding electric signal data as XH1, XH2 and HX3 respectively;
Judging whether the electric signal data XH1 is in a preset low-frequency range threshold value [ M1, M2]; the electrical signal data XH1 is marked as a security point; if not, marking the electric signal data XH1 as an early warning point, calculating the minimum difference value between the electric signal data XH1 and the low-frequency range threshold value, and marking the minimum difference value as CZ1;
Judging whether the electric signal data XH2 is in a preset intermediate frequency range threshold value [ M3, M4]; the electrical signal data XH2 is marked as a security point; if not, marking the electric signal data XH2 as an early warning point, calculating the minimum difference value between the electric signal data XH2 and the low-frequency range threshold value, and marking the minimum difference value as CZ2;
judging whether the electric signal data XH3 is in a preset high-frequency range threshold value [ M5, M6]; the electrical signal data XH3 is marked as a security point; and if not, marking the electric signal data XH3 as an early warning point, calculating the minimum difference between the electric signal data XH3 and the low-frequency range threshold value, and marking the minimum difference as CZ3.
And comparing the collected three groups of electric signal data with the corresponding range threshold values, and if the three groups of electric signal data are all in the corresponding range threshold values, indicating that the welding quality is higher.
The generating a prompt mark of the welding point based on the comparison result in the embodiment includes:
Extracting a comparison result, and judging whether an early warning point exists in the comparison result; if not, generating a qualified mark; and generating a prompt mark according to the minimum difference value.
Further generating a cue marker according to the minimum difference value, comprising:
extracting a minimum difference CZ corresponding to the early warning point, calculating a risk coefficient through a formula WX=1.6XCZ1+0.65XCZ2+0.51XCZ 3, and comparing the risk coefficient WX with a preset risk threshold; if the risk coefficient WX is smaller than the risk threshold value, generating a qualified mark; otherwise, generating an early warning mark; the dangerous threshold value can be set according to the use requirement scene of the welding line.
For example: when the electrical signal data XH1 is not present, then the corresponding CZ1 is 0, i.e. when the risk factor wx=α2×cz2+α3×cz3.
And judging whether the welding quality meets the use standard based on the prompt mark comprises the following steps:
The numbers of the early warning marks and the qualified marks in the statistics prompt marks are marked as YJ and HG respectively, and the occupation ratio ZB is calculated through a formula ZB=YJ/HG; comparing the duty ratio ZB with a preset duty ratio threshold; if the duty ratio ZB is smaller than the duty ratio threshold, marking the welding quality as qualified welding; otherwise, the welding quality is marked as unqualified welding.
By setting different duty ratio thresholds, the grade evaluation of the welding seam quality can be performed, and the welding finished product is applied to different scenes according to the grade evaluation, so that the utilization rate of the welding finished product can be ensured.
The partial data in the formula is obtained by removing dimension and taking the numerical value for calculation, and the formula is obtained by simulating a large amount of acquired data through software and is closest to the real situation; the preset parameters and the preset threshold values in the formula are set by those skilled in the art according to actual conditions or are obtained through mass data simulation.
The working principle of the invention is as follows: the laser welding device 1 emits laser beams, the laser beams are collimated through the first plano-convex lens 2, the direction of the laser beams is controlled by the welding vibrating mirror 3 to act on the focusing lens 4 for refocusing, the welding workpiece 5 is welded, the reflection of the welding workpiece 5 generates reflection light, the reflection light irradiates on the beam splitting prism 8, the reflection light transmits through the semi-transparent reverse surface S1 and the semi-transparent reverse surface S2 on the beam splitting prism 8, the second plano-convex lens 7 and the third plano-convex lens 9 and the corresponding first optical filter 12 and the second optical filter 13 irradiate on the first photoelectric detector 6 and the second photoelectric detector 10 respectively, the transmitted light irradiates on the third photoelectric detector 11 through the third optical filter 14, the first photoelectric detector 6, the second photoelectric detector 10 and the third photoelectric detector 11 convert the collected wave bands into electric signal data, and the quality of the welding seam can be reflected through the data processing module.
The above embodiments are only for illustrating the technical method of the present invention and not for limiting the same, and it should be understood by those skilled in the art that the technical method of the present invention may be modified or substituted without departing from the spirit and scope of the technical method of the present invention.
Claims (5)
1. Welding quality real-time monitoring system based on beam splitting prism, characterized by comprising: the welding assembly and the information acquisition assembly are connected with the welding assembly;
The welding assembly comprises a welding workpiece (5) and a welding galvanometer (3) for controlling the direction of a welding light beam, a focusing lens (4) is arranged at the bottom of the welding galvanometer (3) and right above the welding workpiece (5), a first plano-convex lens (2) for collimating the laser light beam is arranged above the welding galvanometer (3), and a laser welder (1) is arranged in the vertical extension direction of the plane of the first plano-convex lens (2);
The information acquisition component is used for acquiring the retro-reflective electric signal data;
The information acquisition component comprises a beam splitting prism (8) used for carrying out band separation on the back reflection generated in the welding process and a third photoelectric detector (11) positioned at one side of the beam splitting prism (8) and used for receiving transmitted light, wherein a second plano-convex lens (7) and a third plano-convex lens (9) used for focusing the reflected light are respectively arranged at the upper side and the lower side of the beam splitting prism (8), a first photoelectric detector (6) and a second photoelectric detector (10) used for receiving the reflected light are respectively arranged in the vertical extension direction of the planes of the second plano-convex lens (7) and the third plano-convex lens (9), and the first photoelectric detector (6), the second photoelectric detector (10) and the third photoelectric detector (11) are used for converting the received reflected light or the transmitted light into corresponding electric signal data;
the system also comprises a data processing module connected with the information acquisition component;
The data processing module: corresponding electric signal data converted by the first photoelectric detector (6), the second photoelectric detector (10) and the third photoelectric detector (11) are obtained, and the corresponding electric signal data are compared with a preset range threshold value to obtain a comparison result; generating a prompt mark of the welding point based on the comparison result; the comparison result comprises a safety point, an early warning point and a minimum difference value corresponding to the early warning point, and the prompt mark comprises a safety mark and an early warning mark; and
Judging whether the welding quality meets the use standard or not based on the prompt mark;
the comparing the corresponding electrical signal data with a preset range threshold value comprises:
Extracting corresponding electric signal data converted by the first photoelectric detector (6), the second photoelectric detector (10) and the third photoelectric detector (11), and marking the corresponding electric signal data as XH1, XH2 and HX3 respectively;
Judging whether the electric signal data XH1 is in a preset low-frequency range threshold value [ M1, M2]; the electrical signal data XH1 is marked as a security point; if not, marking the electric signal data XH1 as an early warning point, calculating the minimum difference value between the electric signal data XH1 and the low-frequency range threshold value, and marking the minimum difference value as CZ1;
Judging whether the electric signal data XH2 is in a preset intermediate frequency range threshold value [ M3, M4]; the electrical signal data XH2 is marked as a security point; if not, marking the electric signal data XH2 as an early warning point, calculating the minimum difference value between the electric signal data XH2 and the low-frequency range threshold value, and marking the minimum difference value as CZ2;
Judging whether the electric signal data XH3 is in a preset high-frequency range threshold value [ M5, M6]; the electrical signal data XH3 is marked as a security point; if not, marking the electric signal data XH3 as an early warning point, calculating the minimum difference between the electric signal data XH3 and the low-frequency range threshold value, and marking the minimum difference as CZ3;
The generating the prompt mark of the welding point based on the comparison result comprises the following steps:
Extracting a comparison result, and judging whether an early warning point exists in the comparison result; if not, generating a qualified mark; generating a prompt mark according to the minimum difference value;
The generating a prompt sign according to the minimum difference value includes:
extracting a minimum difference CZ corresponding to the early warning point, calculating a risk coefficient through a formula WX=alpha 1X CZ1+alpha 2X CZ2+alpha 3X CZ3, and comparing the risk coefficient WX with a preset risk threshold; if the risk coefficient WX is smaller than the risk threshold value, generating a qualified mark; otherwise, generating an early warning mark; wherein α1, α2, and α3 are preset scaling factors, and α1 > α2 > α3.
2. The welding quality real-time monitoring system based on the beam splitter prism according to claim 1, wherein the beam splitter prism (8) is a triangular prism, the cross section of the beam splitter prism (8) is a right triangle, two right-angle sides of the beam splitter prism (8) extend to form a semi-transparent half-back surface S1 and a semi-transparent half-back surface S2 respectively, and a hypotenuse of the beam splitter prism (8) extends to form an anti-reflection surface S3.
3. The welding quality real-time monitoring system based on the beam splitter prism according to claim 2, wherein the semi-transparent and semi-transparent surface S1 is used for reflecting the retro-reflection of the wave band of 350nm-900nm, the semi-transparent surface S2 is used for reflecting the retro-reflection of the wave band of 1000nm-1100nm, and the anti-reflection surface S3 is used for transmitting the retro-reflection of the wave band of 1200nm-2000 nm.
4. The welding quality real-time monitoring system based on the beam splitter prism according to claim 1, wherein a first optical filter (12) used for transmitting a wave band of 350nm-900nm is arranged between the first photoelectric detector (6) and the second plano-convex lens (7), a second optical filter (13) used for transmitting a wave band of 1000nm-1100nm is arranged between the third plano-convex lens (9) and the second photoelectric detector (10), and a third optical filter (14) used for transmitting a wave band of 1200nm-2000nm is arranged between the beam splitter prism (8) and the third photoelectric detector (11).
5. The real-time monitoring system for welding quality based on a beam splitter prism according to claim 1, wherein the determining whether the welding quality meets the usage standard based on the prompt sign comprises:
The numbers of the early warning marks and the qualified marks in the statistics prompt marks are marked as YJ and HG respectively, and the occupation ratio ZB is calculated through a formula ZB=YJ/HG; comparing the duty ratio ZB with a preset duty ratio threshold; if the duty ratio ZB is smaller than the duty ratio threshold, marking the welding quality as qualified welding; otherwise, the welding quality is marked as unqualified welding.
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|---|---|---|---|---|
| US5511060A (en) * | 1993-02-26 | 1996-04-23 | Industrial Technology Research Institute | Magneto-optical head with a three prism beam splitter to split a reflected beam into three beams |
| CN117102712A (en) * | 2023-10-24 | 2023-11-24 | 宁德时代新能源科技股份有限公司 | Laser processing quality monitoring system, method, processing device and readable storage medium |
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| JPH08206859A (en) * | 1995-02-07 | 1996-08-13 | Toshiba Corp | Device for deciding quality of laser welding |
| JP2004085784A (en) * | 2002-08-26 | 2004-03-18 | Hitachi Koki Co Ltd | Beam splitter and laser marking device equipped with the same |
| DE10321894A1 (en) * | 2003-05-07 | 2004-12-02 | Universität Stuttgart | Device for detecting the welding depth in a keyhole during laser welding comprises a beam bundle distributor producing a lateral shear arranged on the light path facing a camera chip |
| JP5300543B2 (en) * | 2009-03-17 | 2013-09-25 | 株式会社ディスコ | Optical system and laser processing apparatus |
| DE102021111349A1 (en) * | 2021-05-03 | 2022-11-03 | Precitec Gmbh & Co. Kg | Method for monitoring a laser welding process and associated laser welding system |
| CN115889975B (en) * | 2023-01-31 | 2024-05-24 | 广东工业大学 | Laser welding process monitoring system and method |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5511060A (en) * | 1993-02-26 | 1996-04-23 | Industrial Technology Research Institute | Magneto-optical head with a three prism beam splitter to split a reflected beam into three beams |
| CN117102712A (en) * | 2023-10-24 | 2023-11-24 | 宁德时代新能源科技股份有限公司 | Laser processing quality monitoring system, method, processing device and readable storage medium |
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Effective date of registration: 20250106 Address after: 1201, Building A, Komron Technology Park, No. 8-1 Guansheng 5th Road, Luhu Community, Guanhu Street, Longhua District, Shenzhen City, Guangdong Province, 518000 Patentee after: SHENZHEN JPT OPTO-ELECTRONICS Co.,Ltd. Country or region after: China Address before: 518000, Building B1, Block B, Phase I, Baoneng Science and Technology Park (South Zone), Qinghu Industrial Zone, Gangtou Community, Bantian Street, Longgang District, Shenzhen City, Guangdong Province, China, 901-06 Patentee before: Shenzhen Jiuzhou Intelligent Welding Future Technology Co.,Ltd. Country or region before: China |