CN117943732B - Welding quality detection method, system, device and storage medium - Google Patents
Welding quality detection method, system, device and storage medium Download PDFInfo
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- CN117943732B CN117943732B CN202410339559.0A CN202410339559A CN117943732B CN 117943732 B CN117943732 B CN 117943732B CN 202410339559 A CN202410339559 A CN 202410339559A CN 117943732 B CN117943732 B CN 117943732B
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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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
- B23K31/125—Weld quality monitoring
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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
- B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
- G01D21/02—Measuring two or more variables by means not covered by a single other subclass
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Abstract
The invention provides a welding quality detection method, a welding quality detection system, a welding quality detection device and a storage medium, and relates to the technical field of welding. The method comprises the following steps: sampling the conductor parts welded in the current processing batch to obtain a plurality of sample conductor parts; obtaining a first test current value and a reference current value between each group of test points; obtaining a plurality of conductor components to be tested; setting a plurality of first sampling points; measuring a first distance of a first sampling point in a section of welding line parallel to the plane of the test table through the laser range finder; setting a plurality of second sampling points, and acquiring position coordinates of the laser probe in a first plane; determining a weld appearance score; testing a second test current value of each set of test points; determining a welding deformation resistance score; a weld quality condition of a current process lot of conductor components is determined. According to the invention, the detection can be completed by using the universal measuring equipment without depending on special complex detecting equipment, and the convenience and accuracy of the detection are improved.
Description
Technical Field
The present invention relates to the field of welding technologies, and in particular, to a method, a system, an apparatus, and a storage medium for detecting welding quality.
Background
In the related art, CN112756840a provides a welding quality detection system. Comprising the following steps: the surface layer data acquisition module: the method comprises the steps of acquiring a welding line image of a welded body after welding, and determining the surface welding state of a welding line according to the welding line image; an inner layer data acquisition module: the method comprises the steps of irradiating a welded seam of a welded body by X-rays, acquiring a digital image of the welded seam, and determining the internal welding state of the welded seam according to the digital image; welding internal data acquisition module: the method comprises the steps of obtaining welding parameters in the welding process of a welding body, and generating a state model according to the welding parameters; model previewing module: the welding method comprises the steps of generating a state model according to a welding result of a welding body, and performing weld previewing and previewing data; and a comparison module: and the welding quality is determined by comparing the surface welding state, the internal welding state and the welding parameters.
CN114952068a relates to the field of welding technology, in particular to a welding quality detection method and detection device, a welding device and a control method thereof. The welding quality detection method comprises the following steps: acquiring an ultrasonic chromaticity image of a part to be detected containing a welding part, wherein different degrees of color correspond to different interface combination degrees in the ultrasonic chromaticity image; selecting a welding area from the ultrasonic chromaticity image; acquiring chromaticity amplitude values of each point included in a welding area; and if the number of points with the chromaticity amplitude smaller than the first chromaticity threshold value in the points included in the welding area is larger than the first preset number, judging that the welding quality of the welding part is qualified. In the method, the ultrasonic chromaticity image of the part to be detected is obtained, and different degrees of chromaticity correspond to different interface bonding degrees in the ultrasonic chromaticity image, so that the interface bonding degree of the welding part, namely the welding quality, can be reflected through the difference of chromaticity in the image, and the detection of the welding quality is more accurate.
In the related art, conventional welding quality inspection methods mainly include X-ray inspection, ultrasonic inspection, etc., which generally require complicated inspection equipment, thereby increasing production costs and inspection cycles.
The information disclosed in the background section of the application is only for enhancement of understanding of the general background of the application and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
Disclosure of Invention
The embodiment of the invention provides a welding quality detection method, a welding quality detection system, a welding quality detection device and a storage medium, which can solve the technical problem of relying on complex detection equipment.
According to a first aspect of the present invention, there is provided a method of detecting welding quality, comprising: sampling the conductor parts welded in the current processing batch to obtain a plurality of sample conductor parts; setting a plurality of groups of test points on two sides of a welding seam of a sample conductor component, respectively applying preset voltage to each group of test points to obtain a first test current value between each group of test points, and applying the preset voltage between any two test points on the same side of the welding seam to obtain a reference current value of the sample conductor component; screening the sample conductor parts according to the first test current value and the reference current value to obtain a plurality of conductor parts to be tested; setting a plurality of first sampling points on a welding line of the conductor component to be tested, and placing the conductor component to be tested on a test bench, so that at least one section of the welding line is parallel to the plane of the test bench, wherein a laser range finder is arranged right above the test bench, a laser probe of the laser range finder can translate in a first plane parallel to the plane of the test bench, and laser emitted by the laser probe is perpendicular to the plane of the test bench; measuring a first distance of a first sampling point in a section of welding line parallel to the plane of the test table through a laser range finder; setting a plurality of second sampling points on the edge of a welding seam of the conductor component to be measured, enabling a laser probe of the laser range finder to translate, enabling laser emitted by the laser probe to irradiate the second sampling points, and obtaining position coordinates of the laser probe in the first plane; determining a welding appearance score according to the first distance corresponding to the first sampling point and the position coordinate corresponding to the second sampling point; fixing a part of one side of a welding line of the conductor component to be tested, applying thrust to the other side, and testing a second test current value of each group of test points when the thrust is applied, wherein the application direction of the thrust is perpendicular to the extending direction of the welding line; determining a welding deformation resistance score according to the first test current value and the second test current value; and determining the welding quality condition of the conductor parts in the current processing batch according to the welding deformation resistance score, the welding appearance score and the quantity ratio of the conductor parts to be detected to the sample conductor parts.
According to a second aspect of the present invention, there is provided a welding quality detection system, the system comprising: the sample conductor component module is used for sampling the conductor components welded in the current processing batch to obtain a plurality of sample conductor components; the first test current value module is used for arranging a plurality of groups of test points on two sides of a welding seam of the sample conductor component, respectively applying preset voltage to each group of test points to obtain a first test current value between each group of test points, and applying the preset voltage between any two test points on the same side of the welding seam to obtain a reference current value of the sample conductor component; the conductor component module to be tested is used for screening the sample conductor components according to the first test current value and the reference current value to obtain a plurality of conductor components to be tested; the device comprises a first sampling point module, a first sampling point module and a second sampling point module, wherein the first sampling points are arranged on a welding line of a conductor component to be tested, the conductor component to be tested is placed on a test bench, at least one section of the welding line is parallel to the plane of the test bench, a laser range finder is arranged right above the test bench, a laser probe of the laser range finder can translate in a first plane parallel to the plane of the test bench, and laser emitted by the laser probe is perpendicular to the plane of the test bench; the first distance module is used for measuring a first distance of a first sampling point in a section of welding line parallel to the plane of the test bench through the laser range finder; the position coordinate module is used for setting a plurality of second sampling points on the edge of the welding seam of the conductor component to be detected, enabling the laser probe of the laser range finder to translate, enabling laser emitted by the laser probe to irradiate to the second sampling points, and obtaining position coordinates of the laser probe in the first plane; the welding appearance scoring module is used for determining welding appearance scoring according to the first distance corresponding to the first sampling point and the position coordinate corresponding to the second sampling point; the second test current value module is used for fixing a part of one side of the welding line of the conductor component to be tested, applying thrust to the other side, and testing a second test current value of each group of test points when the thrust is applied, wherein the application direction of the thrust is perpendicular to the extending direction of the welding line; the welding deformation resistance scoring module is used for determining welding deformation resistance scores according to the first test current value and the second test current value; and the welding quality condition module is used for determining the welding quality condition of the conductor parts of the current processing batch according to the welding deformation resistance score, the welding appearance score and the quantity ratio of the conductor parts to be tested to the sample conductor parts.
According to a third aspect of the present invention, there is provided a welding quality detection apparatus comprising: a processor; a memory for storing processor-executable instructions; wherein the processor is configured to invoke the instructions stored by the memory to perform the method of detecting weld quality.
According to a fourth aspect of the present invention, there is provided a computer readable storage medium having stored thereon computer program instructions which, when executed by a processor, implement the method of detecting weld quality.
The technical effects are as follows: according to the invention, the welded conductor parts are sampled, the conductor parts to be tested are screened according to the first test current value and the reference current value, the welding appearance score is determined by utilizing the measuring distance mode, and the welding quality of the conductor parts in the current processing batch is evaluated by combining the welding deformation resistance score and the number ratio of the conductor parts to be tested to the sample conductor parts. The evaluation result can find problems in time, and the detection can be completed by using general measuring equipment without depending on special complex detecting equipment, so that the convenience of detection is improved, the whole welding quality level can be improved, and the optimization of the production process and the continuous improvement of quality control are guided. When the conductor components to be tested are screened, the screening score of the ith sample conductor component can be set through the first test current value and the reference current value, so that the sample conductor component which is higher than or equal to the preset screening threshold value is screened out as the conductor components to be tested, the conductor components to be tested with good conductivity of the whole welding seam can be accurately screened out, the sample conductor components with the defect of the whole welding seam and greatly reduced conductivity are removed, the welding quality of the conductor components to be tested reaches a certain requirement, and further the welding quality is detected. When the appearance score of the height of the welding seam is determined, the appearance score of the height of the welding seam of each conductor part to be measured can be obtained through the first distance, the first distance average value and the first distance standard deviation, and the larger the score is, the more uniform the height of the surface of the welding seam is indicated, otherwise, the smaller the score is, the larger the height difference of the surface of the welding seam is indicated, so that the uniformity in the aspect of the height of the welding seam is accurately and objectively reflected, and the quality condition of welding is objectively reflected. When the appearance score of the welding seam edge is determined, the minimum distance between each second sampling point and the welding seam edge curve can be calculated to determine the approaching degree of the welding seam edge and the theoretical wavy line, so that the appearance score of the welding seam edge of each conductor part to be measured is determined, the flatness of the welding seam edge can be accurately and objectively evaluated, and the welding seam edge measuring device can be used for timely finding the quality problem of the welding seam edge in the welding process. When the welding deformation resistance score is determined, the undetermined coefficient can be solved through the force of repeatedly applying the thrust force and the second test current value, and the relation between the conductivity and the thrust force at the two sides of the welding seam of the conductor part to be measured can be better analyzed, so that the welding deformation resistance score can be obtained, the force of the thrust force required by the relative error of the resistance values at the two sides of the welding seam can be accurately described, and the deformation resistance or the thrust force resistance of the conductor part to be measured can be accurately represented. When the welding quality condition score of the conductor parts of the current processing batch is determined, the welding quality condition score of the conductor parts of the current processing batch can be calculated based on the quantity ratio of the conductor parts to be detected to the sample conductor parts, so that the overall welding quality condition of the conductor parts of the current processing batch can be quickly known, the welding quality can be monitored and controlled in the production process, problems can be timely found, measures can be taken for improvement, and the welding quality can be improved.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. Other features and aspects of the present invention will become apparent from the following detailed description of exemplary embodiments, which proceeds with reference to the accompanying drawings.
Drawings
In order to more clearly illustrate the embodiments of the invention or the solutions of the prior art, the drawings which are necessary for the description of the embodiments or the prior art will be briefly described below, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other embodiments may be obtained from these drawings without inventive effort to a person skilled in the art,
Fig. 1 schematically shows a flow chart of a method for detecting weld quality according to an embodiment of the invention;
Fig. 2 schematically shows a block diagram of a welding quality detection system according to an embodiment of the invention.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent 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.
The technical scheme of the invention is described in detail below by specific examples. The following embodiments may be combined with each other, and some embodiments may not be repeated for the same or similar concepts or processes.
Fig. 1 schematically shows a flow chart of a method for detecting welding quality according to an embodiment of the invention, the method comprising: step S101, sampling the welded conductor parts of the current processing batch to obtain a plurality of sample conductor parts; step S102, setting a plurality of groups of test points on two sides of a welding seam of a sample conductor component, respectively applying preset voltage to each group of test points to obtain a first test current value between each group of test points, and applying the preset voltage between any two test points on the same side of the welding seam to obtain a reference current value of the sample conductor component; step S103, screening the sample conductor parts according to the first test current value and the reference current value to obtain a plurality of conductor parts to be tested; step S104, a plurality of first sampling points are arranged on a welding line of the conductor component to be tested, the conductor component to be tested is placed on a test bench, at least one section of the welding line is parallel to the plane of the test bench, a laser range finder is arranged right above the test bench, a laser probe of the laser range finder can translate in a first plane parallel to the plane of the test bench, and laser emitted by the laser probe is perpendicular to the plane of the test bench; step S105, measuring a first distance of a first sampling point in a section of welding line parallel to the plane of the test bench by a laser range finder; step S106, a plurality of second sampling points are arranged on the edge of the welding seam of the conductor component to be detected, the laser probe of the laser range finder is translated, laser emitted by the laser probe is irradiated to the second sampling points, and the position coordinates of the laser probe in the first plane are obtained; step S107, determining a welding appearance score according to the first distance corresponding to the first sampling point and the position coordinate corresponding to the second sampling point; step S108, fixing a part of one side of the welding line of the conductor component to be tested, applying thrust to the other side, and testing a second test current value of each group of test points when the thrust is applied, wherein the application direction of the thrust is perpendicular to the extending direction of the welding line; step S109, determining welding deformation resistance scores according to the first test current value and the second test current value; step S110, determining the welding quality condition of the conductor parts of the current processing batch according to the welding deformation resistance score, the welding appearance score and the quantity ratio of the conductor parts to be detected to the sample conductor parts.
According to the method for detecting welding quality, the welded conductor parts are sampled, the conductor parts to be detected are screened according to the first test current value and the reference current value, the welding appearance score is determined by utilizing the measuring distance mode, and the welding quality of the conductor parts in the current processing batch is evaluated by combining the welding deformation resistance score and the quantity ratio of the conductor parts to be detected to the sample conductor parts. The evaluation result can find problems in time, and the detection can be completed by using general measuring equipment without depending on special complex detecting equipment, so that the convenience of detection is improved, the whole welding quality level can be improved, and the optimization of the production process and the continuous improvement of quality control are guided.
According to one embodiment of the present invention, in step S101, a plurality of sample conductor parts are randomly selected from the welded conductor parts of the current processing lot to be detected and evaluated. By detecting the sample conductor member, the welding quality level of the current processing lot can be known as a whole.
According to one embodiment of the present invention, in step S102, the preset voltage is a relatively small voltage value, for example, a voltage of a general battery. Applying a preset voltage to a group of test points on two sides of the welding seam so as to obtain a first test current value, and applying a preset voltage to the test points on the same side of the welding seam so as to obtain a reference current value. Wherein the first test current value determines the conductivity between the two sides of the weld of the sample conductor member and the reference current value determines the conductivity of the sample conductor member without the weld. When voltage is applied, a device consisting of a power supply, an electric wire and an electrode can be used, the electrode can be connected to two ends of the power supply through the electric wire, so that the electrode contacts with the test point, the voltage can be applied to the test point, and the current on the electric wire can be measured, so that the first test current value and the reference current value can be obtained.
According to one embodiment of the present invention, in step S103, the welding quality and connection stability of the sample conductor parts may be evaluated by comparing and analyzing the first test current value and the reference current value, so as to determine which sample conductor parts meet the quality standard, and may be further tested and evaluated, i.e. become conductor parts to be tested.
According to one embodiment of the present invention, the screening of the sample conductor part according to the first test current value and the reference current value to obtain a plurality of conductor parts to be tested includes: obtaining a screening score for the ith sample conductor part according to equation (1)，
（1）
Wherein,In order for the voltage to be a preset value,For a first test current value between the j-th set of test points of the i-th sample conductor member,N is the number of groups of test points, max is a maximum value taking function, j is less than or equal to n, and i, j and n are positive integers; and determining the sample conductor part with the screening score higher than or equal to the preset screening threshold value as the conductor part to be tested.
According to one embodiment of the present invention, in equation (1),Is the ratio of the preset voltage to the first test current value between the j-th set of test points of the i-th sample conductor member, i.e., represents the resistance value between the j-th set of test points on both sides of the weld joint of the i-th sample conductor member when the preset voltage is applied.The ratio of the preset voltage to the reference current value of the i-th sample conductor member, that is, the resistance value of the material of the i-th sample conductor member on the same side as the weld joint, that is, the resistance value of the material of the sample conductor member itself, when the preset voltage is applied.Representing the relative error of the resistance value between the j-th set of test points of the i-th sample conductor member and the resistance value of the material of the i-th sample conductor member itself.The maximum value of the relative errors corresponding to all groups of test points, namely the worst conductivity value of the two sides of the weld joint of the ith sample conductor component, is shown.The maximum relative error, i.e., the similarity of the conductivity properties of the ith sample conductor part and itself, on both sides of the weld is subtracted from 1 to obtain a screening score for the ith sample conductor part. And further, the sample conductor component with good conductivity of the whole welding seam can be screened through screening and grading, the conductor component to be tested is obtained, and the sample conductor component with the defect of the whole welding seam and greatly reduced conductivity is removed.
Through the mode, the screening score of the ith sample conductor part can be set through the first test current value and the reference current value, the sample conductor part which is higher than or equal to the preset screening threshold value is screened out to serve as the conductor part to be tested, the conductor part to be tested with good conductivity of the whole welding seam can be accurately screened out, the sample conductor part with the defect of the whole welding seam and the conductivity greatly reduced due to the defect of the whole welding seam is removed, the welding quality of the conductor part to be tested reaches a certain requirement, and further the welding quality of the conductor part to be tested is detected.
According to an embodiment of the present invention, in step S104, the laser rangefinder is an instrument for measuring distance by using laser technology, which has high accuracy, and can obtain measurement results in millimeter level or even micrometer level. A plurality of first sampling points are provided on the weld, for example, the first sampling points may be provided on a centerline of the weld, such that a difference in height of the plurality of first sampling points of the weld surface is measured using a laser rangefinder. The placement of at least one section of the weld parallel to the plane of the test bench can improve the accuracy and reliability of the measurement.
According to one embodiment of the present invention, in step S105, the first distance may be measured by laser light emitted from the laser range finder. And acquiring the height difference data of the welding seam surface through the first distances corresponding to the first sampling points, and providing important references for the evaluation of welding quality.
According to an embodiment of the present invention, in step S106, the laser probe of the laser rangefinder is moved to align the laser emitted by the laser probe with the second sampling point on the edge of the weld seam, so as to obtain the position coordinate of the laser probe in the first plane, where the position coordinate of the laser probe in the first plane is a two-dimensional position coordinate and is consistent with the two-dimensional position coordinate of the second sampling point, so that the position coordinate of each second sampling point can be obtained in this step, and data support is provided for further welding quality assessment.
According to one embodiment of the present invention, in step S107, height difference data of the weld surface may be obtained by measuring a first distance corresponding to the first sampling point using the laser rangefinder. In addition, by measuring the position coordinates corresponding to the second sampling point, whether the welding seam edge is uniform or not can be judged. In combination with these two sets of data, a weld appearance score may be determined. The score may be used to evaluate the quality of the appearance of the weld.
According to one embodiment of the present invention, step S107 includes: determining a first distance mean value and a first distance standard deviation of first distances corresponding to a plurality of first sampling points of a plurality of conductor components to be tested; obtaining the welding seam height appearance scores of the conductor components to be tested according to the first distance average value, the first distance standard deviation and the first distances corresponding to the first sampling points of the conductor components to be tested; fitting according to position coordinates corresponding to second sampling points on the weld edges of all the conductor components to be tested, and obtaining curves of the weld edges; obtaining the minimum distance between the position coordinate corresponding to the second sampling point and the curve of the welding seam edge; determining the appearance scores of the welding seam edges of all the conductor components to be tested according to the minimum distance; and determining the welding seam appearance scores of the conductor components to be tested according to the welding seam height appearance scores and the welding seam edge appearance scores.
According to one embodiment of the invention, the welding seam height appearance score is obtained by calculating the first distance mean value and the first distance standard deviation of the plurality of conductor components to be tested and combining the first distances corresponding to the first sampling points. Fitting the position coordinates corresponding to the second sampling points on the welding seam edge to obtain a curve of the welding seam edge, further obtaining the minimum distance between the position coordinates of the second sampling points and the curve of the welding seam edge, determining the welding seam edge appearance score according to the minimum distance, and finally determining the welding seam appearance score of each conductor part to be tested according to the welding seam height appearance score and the welding seam edge appearance score, thereby comprehensively evaluating the quality of the welding appearance.
According to one embodiment of the present invention, obtaining a weld height appearance score of each conductor component to be tested according to the first distance average value, the first distance standard deviation, and first distances corresponding to a plurality of first sampling points of the conductor components to be tested, includes: obtaining a weld height appearance score of the s-th conductor part to be tested according to the formula (2)，
（2）
Wherein,For a first distance corresponding to a kth first sampling point on the weld joint of an s-th conductor component to be tested,As a result of the first distance mean,As a result of the first distance standard deviation,In order to be a preset multiple of the number,For the number of the first sampling points on the welding line of the s-th conductor component to be tested, k is less than or equal toAnd k andAll are positive integers, if is a conditional function, max is a maximum function, and min is a minimum function.
According to one embodiment of the present invention, in equation (2),Representing that the first distance corresponding to the kth first sampling point on the welding line of the s-th conductor part to be tested is equal toAnd if the condition function value is 1, otherwise, the condition function value is 0. Wherein, the preset multipleCan be set to 3, and the present invention is not limited thereto.Indicating that the first distance corresponding to the first sampling point on all welding seams of the s-th conductor part to be tested is as followsThe ratio of the number of sampling points in the inner part to the number of first sampling points on the weld joint of the s-th conductor part to be tested. The larger the value, the fewer the number of first sampling points representing a larger difference from the mean, the more uniform the height of the weld surface.Representing the ratio of the difference between the maximum value of the first distance and the minimum value of the first distance corresponding to a plurality of first sampling points on the weld joint of the s-th conductor component to be measured to the average value of the first distance, namely, the relative difference between the maximum value of the first distance and the minimum value of the first distance, wherein the smaller the relative difference is, the more uniform the height of the weld joint surface is represented. Thus, the first and second substrates are bonded together,The greater the value of (2), the more uniform the height of the weld surface. And multiplying the two items to obtain the welding seam height appearance score of the s-th conductor component to be tested.
In this way, the welding seam height appearance score of each conductor component to be detected can be obtained through the first distance, the first distance average value and the first distance standard deviation, and the larger the score is, the more uniform the height of the welding seam surface is indicated, otherwise, the smaller the score is, the larger the height difference of the welding seam surface is indicated, so that the uniformity in the aspect of the welding seam height is accurately and objectively reflected, and the welding quality condition is objectively reflected.
According to one embodiment of the invention, determining the weld edge appearance score of each conductor part to be tested according to the minimum distance comprises: determining a weld edge appearance score for the s-th to-be-tested conductor component according to equation (3)，
（3）
Wherein,For the minimum distance between the t second sampling point on the weld edge of the s-th conductor component to be tested and the curve of the weld edge,In order to preset the distance threshold value,T is less than or equal to the number of second sampling points on the weld edge of the s-th conductor component to be testedAnd t andAre all positive integers.
According to one embodiment of the invention, the weld edge is theoretically wavy line, and the fluctuation range of the theoretical wavy line can be set as。
According to one embodiment of the invention, the weld edge is theoretically a wavy line, and when the curve of the weld edge is obtained by fitting, the functional expression of the curve of the weld edge is in the form of a straight line, which may be a straight line passing through the wavy line, in other words, the wavy line of the weld edge fluctuates around the straight line obtained by fitting. In the formula (3) of the present invention,The absolute value of the difference between the minimum distance maximum value between the t second sampling point on the weld edge of the s-th conductor component to be tested and the curve of the weld edge and the preset distance threshold, namely, the difference between the distance between the second sampling point with the largest deviation from the straight line and the straight line, which is 2 times of the distance between the second sampling point and the curve of the weld edge and the fluctuation range of the wave line is represented.I.e. the relative value of the gap, the smaller the relative value, the closer the weld edge is to the theoretical wavy line, or the less the fluctuation is compared to the theoretical wavy line, the smoother the edge.The appearance score of the welding seam edge of the s-th conductor part to be detected is shown, wherein the score is closer to 1, which indicates that the welding seam edge is closer to a theoretical wavy line, or the fluctuation of the welding seam edge is smaller than that of the theoretical wavy line, the edge is smoother, and the appearance quality is better; the closer to 0, the more irregular the weld edge, the poorer the appearance quality.
By the method, the minimum distance between each second sampling point and the weld edge curve can be calculated, the proximity degree of the weld edge and the theoretical wavy line can be determined, the weld edge appearance score of each conductor part to be tested can be further determined, the flatness of the weld edge can be accurately and objectively evaluated, and the method can be used for finding the quality problem of the weld edge in the welding process in time.
According to an embodiment of the present invention, in step S108, by applying a thrust force perpendicular to the extending direction of the weld joint, the influence of a lateral thrust force encountered by the conductor component to be tested in use may be simulated, so that the weld joint may be broken, thereby affecting the conductivity of both sides of the weld joint, and therefore, the quality stability when the weld joint receives the thrust force may be described using the change in conductivity of both sides of the weld joint when the thrust force is applied. The second test current value is tested while the thrust is applied, and the current change condition of the conductor component to be tested under different thrust can be observed, so that the stability of welding quality is judged.
According to one embodiment of the present invention, in step S109, a weld deformation resistance score may be obtained by the first test current value and the second test current value. The score may be used to describe the stability of the weld quality of the conductor component under test when subjected to external thrust.
According to one embodiment of the invention, determining a weld deformation resistance score from the first and second test current values comprises: determining a coefficient equation to be determined according to the formula (4),
（4）
Wherein,For the force of the x-th applied thrust,In order for the voltage to be a preset value,For a first test current value between the j-th set of test points of the s-th conductor component to be tested,When thrust is applied for the xth time, a second test current value between the j-th group of test points of the s-th conductor component to be tested, n is the group number of the test points, j is less than or equal to n, and s, j and n are positive integers,The coefficient is the undetermined coefficient corresponding to the s-th conductor component to be tested; in the process of repeatedly applying the thrust, obtaining the strength of repeatedly applying the thrust and a second test current value; solving the undetermined coefficient through the force of applying the thrust for a plurality of times and a second test current value to obtain a solution value of the undetermined coefficient; determining a weld strain resistance score for the s-th to-be-tested conductor component according to equation (5)，
（5）
Wherein,Is thatIs used to solve the problem of the (c) for the (c),Is a preset resistance change coefficient.
According to one embodiment of the present invention, in equation (4),And representing the relative error between the resistance value between the j-th group of test points of the s-th conductor component to be tested when no thrust is applied and the resistance value between the j-th group of test points of the s-th conductor component to be tested when the thrust is applied for the x-th time.Indicating the maximum value of the relative error of all the test points, i.e. the maximum variation which results in the occurrence of the resistance value when the pushing force is applied for the x-th time. Equation (4) may then represent the relationship between the force of the thrust force and the maximum amount of change that occurs in the resistance value. The greater the force with which the thrust is applied, the greater the likelihood of cracking of the weld, i.e., the greater the force with which the thrust is applied, which can result in a greater relative error in the resistance values described above. The undetermined coefficient can be solved according to the strength of the repeated application of the thrust force and the second test current value, so as to obtain a solved value of the undetermined coefficient. The larger the value, the larger the force of the thrust force required for causing the relative error of the resistance value, and the stronger the deformation or thrust resistance of the conductor member to be measured.
According to one embodiment of the present invention, in equation (5),And (3) representing the ratio between the solution value of the undetermined coefficient of the s-th to-be-measured conductor component and the preset resistance change coefficient, namely, the welding deformation resistance score of the s-th to-be-measured conductor component. When the score is larger, the actual deformation resistance of the conductor component to be measured is higher, namely the welding quality is better. Otherwise, when the score is smaller, the actual deformation resistance of the conductor component to be tested is poorer, namely the welding quality is poorer.
By means of the method, the undetermined coefficient can be solved through the force of applying the thrust force and the second test current value for many times, the relation between the conductivity and the thrust force on two sides of the welding seam of the conductor part to be tested can be better analyzed, so that the welding deformation resistance score can be obtained, the force of the thrust force required by the relative error of the resistance values on two sides of the welding seam can be accurately described, and the deformation resistance or the thrust force resistance of the conductor part to be tested can be accurately represented.
According to one embodiment of the present invention, in step S110, a comprehensive assessment of the weld quality of the conductor part to be tested is obtained by a comprehensive consideration of the weld deformation resistance score and the weld appearance score. Wherein the weld deformation resistance score reflects the performance of the conductor component under deformation or stress, and the weld appearance score provides an assessment of the appearance and quality of the weld. Meanwhile, the number ratio of the conductor component to be measured to the sample conductor component is considered, so that the overall welding quality condition of the batch can be obtained.
According to one embodiment of the present invention, determining the welding quality condition of the conductor part of the current processing batch according to the welding deformation resistance score, the welding appearance score, and the number ratio of the conductor part to be measured to the sample conductor part comprises: determining a welding quality condition score Q for the conductor component of the current process lot according to equation (6),
（6）
Wherein,Scoring the welding appearance of the s-th conductor part to be tested,Scoring the welding deformation resistance of the s-th conductor part to be measured, wherein p is the number ratio of the conductor part to be measured to the sample conductor part,AndAnd m is the number of the conductor components to be detected, s is less than or equal to m, and s and m are positive integers.
According to one embodiment of the present invention, in equation (6),And representing the average value of the welding appearance scores and the welding deformation resistance scores of all the conductor components to be tested after weighted summation.And (3) representing the average value obtained by multiplying the number ratio of the conductor components to be tested to the sample conductor components by the weighted sum of the welding appearance scores and the welding deformation resistance scores of all the conductor components to be tested, namely, the welding quality condition scores of the conductor components of the current processing batch. The higher the score, the better the weld quality condition of the conductor parts of the current processing lot. Conversely, the lower the score, the worse the weld quality condition of the conductor parts of the current processing lot.
By the method, the welding quality condition score of the conductor parts in the current processing batch can be calculated based on the quantity ratio of the conductor parts to be detected to the sample conductor parts, the overall welding quality condition of the conductor parts in the current processing batch can be quickly known, the welding quality can be monitored and controlled in the production process, problems can be timely found, measures can be taken for improvement, and the welding quality can be improved.
According to the method for detecting welding quality, the welded conductor parts are sampled, the conductor parts to be detected are screened according to the first test current value and the reference current value, the welding appearance score is determined by utilizing the measuring distance mode, and the welding quality of the conductor parts in the current processing batch is evaluated by combining the welding deformation resistance score and the quantity ratio of the conductor parts to be detected to the sample conductor parts. The evaluation result can find problems in time, and the detection can be completed by using general measuring equipment without depending on special complex detecting equipment, so that the convenience of detection is improved, the whole welding quality level can be improved, and the optimization of the production process and the continuous improvement of quality control are guided. When the conductor components to be tested are screened, the screening score of the ith sample conductor component can be set through the first test current value and the reference current value, so that the sample conductor component which is higher than or equal to the preset screening threshold value is screened out as the conductor components to be tested, the conductor components to be tested with good conductivity of the whole welding seam can be accurately screened out, the sample conductor components with the defect of the whole welding seam and greatly reduced conductivity are removed, the welding quality of the conductor components to be tested reaches a certain requirement, and further the welding quality is detected. When the appearance score of the height of the welding seam is determined, the appearance score of the height of the welding seam of each conductor part to be measured can be obtained through the first distance, the first distance average value and the first distance standard deviation, and the larger the score is, the more uniform the height of the surface of the welding seam is indicated, otherwise, the smaller the score is, the larger the height difference of the surface of the welding seam is indicated, so that the uniformity in the aspect of the height of the welding seam is accurately and objectively reflected, and the quality condition of welding is objectively reflected. When the appearance score of the welding seam edge is determined, the minimum distance between each second sampling point and the welding seam edge curve can be calculated to determine the approaching degree of the welding seam edge and the theoretical wavy line, so that the appearance score of the welding seam edge of each conductor part to be measured is determined, the flatness of the welding seam edge can be accurately and objectively evaluated, and the welding seam edge measuring device can be used for timely finding the quality problem of the welding seam edge in the welding process. When the welding deformation resistance score is determined, the undetermined coefficient can be solved through the force of repeatedly applying the thrust force and the second test current value, and the relation between the conductivity and the thrust force at the two sides of the welding seam of the conductor part to be measured can be better analyzed, so that the welding deformation resistance score can be obtained, the force of the thrust force required by the relative error of the resistance values at the two sides of the welding seam can be accurately described, and the deformation resistance or the thrust force resistance of the conductor part to be measured can be accurately represented. When the welding quality condition score of the conductor parts of the current processing batch is determined, the welding quality condition score of the conductor parts of the current processing batch can be calculated based on the quantity ratio of the conductor parts to be detected to the sample conductor parts, so that the overall welding quality condition of the conductor parts of the current processing batch can be quickly known, the welding quality can be monitored and controlled in the production process, problems can be timely found, measures can be taken for improvement, and the welding quality can be improved.
Fig. 2 schematically shows a block diagram of a welding quality detection system according to an embodiment of the invention, the system comprising: the sample conductor component module is used for sampling the conductor components welded in the current processing batch to obtain a plurality of sample conductor components; the first test current value module is used for arranging a plurality of groups of test points on two sides of a welding seam of the sample conductor component, respectively applying preset voltage to each group of test points to obtain a first test current value between each group of test points, and applying the preset voltage between any two test points on the same side of the welding seam to obtain a reference current value of the sample conductor component; the conductor component module to be tested is used for screening the sample conductor components according to the first test current value and the reference current value to obtain a plurality of conductor components to be tested; the device comprises a first sampling point module, a first sampling point module and a second sampling point module, wherein the first sampling points are arranged on a welding line of a conductor component to be tested, the conductor component to be tested is placed on a test bench, at least one section of the welding line is parallel to the plane of the test bench, a laser range finder is arranged right above the test bench, a laser probe of the laser range finder can translate in a first plane parallel to the plane of the test bench, and laser emitted by the laser probe is perpendicular to the plane of the test bench; the first distance module is used for measuring a first distance of a first sampling point in a section of welding line parallel to the plane of the test bench through the laser range finder; the position coordinate module is used for setting a plurality of second sampling points on the edge of the welding seam of the conductor component to be detected, enabling the laser probe of the laser range finder to translate, enabling laser emitted by the laser probe to irradiate to the second sampling points, and obtaining position coordinates of the laser probe in the first plane; the welding appearance scoring module is used for determining welding appearance scoring according to the first distance corresponding to the first sampling point and the position coordinate corresponding to the second sampling point; the second test current value module is used for fixing a part of one side of the welding line of the conductor component to be tested, applying thrust to the other side, and testing a second test current value of each group of test points when the thrust is applied, wherein the application direction of the thrust is perpendicular to the extending direction of the welding line; the welding deformation resistance scoring module is used for determining welding deformation resistance scores according to the first test current value and the second test current value; and the welding quality condition module is used for determining the welding quality condition of the conductor parts of the current processing batch according to the welding deformation resistance score, the welding appearance score and the quantity ratio of the conductor parts to be tested to the sample conductor parts.
According to an embodiment of the present invention, there is provided a welding quality detection apparatus including: a processor; a memory for storing processor-executable instructions; wherein the processor is configured to invoke the instructions stored by the memory to perform the method of detecting weld quality.
According to one embodiment of the invention, a computer readable storage medium is provided, having stored thereon computer program instructions which, when executed by a processor, implement the method of detecting weld quality.
The present invention may be a method, apparatus, system, and/or computer program product. The computer program product may include a computer readable storage medium having computer readable program instructions embodied thereon for performing various aspects of the present invention.
It will be appreciated by persons skilled in the art that the embodiments of the invention described above and shown in the drawings are by way of example only and are not limiting. The objects of the present invention have been fully and effectively achieved. The functional and structural principles of the present invention have been shown and described in the examples and embodiments of the invention may be modified or practiced without departing from the principles described.
Claims (6)
1. A method of detecting weld quality, comprising: sampling the conductor parts welded in the current processing batch to obtain a plurality of sample conductor parts; setting a plurality of groups of test points on two sides of a welding seam of a sample conductor component, respectively applying preset voltage to each group of test points to obtain a first test current value between each group of test points, and applying the preset voltage between any two test points on the same side of the welding seam to obtain a reference current value of the sample conductor component; screening the sample conductor parts according to the first test current value and the reference current value to obtain a plurality of conductor parts to be tested; setting a plurality of first sampling points on a welding line of the conductor component to be tested, and placing the conductor component to be tested on a test bench, so that at least one section of the welding line is parallel to the plane of the test bench, wherein a laser range finder is arranged right above the test bench, a laser probe of the laser range finder can translate in a first plane parallel to the plane of the test bench, and laser emitted by the laser probe is perpendicular to the plane of the test bench; measuring a first distance of a first sampling point in a section of welding line parallel to the plane of the test table through a laser range finder; setting a plurality of second sampling points on the edge of a welding seam of the conductor component to be measured, enabling a laser probe of the laser range finder to translate, enabling laser emitted by the laser probe to irradiate the second sampling points, and obtaining position coordinates of the laser probe in the first plane; determining a welding appearance score according to the first distance corresponding to the first sampling point and the position coordinate corresponding to the second sampling point; fixing a part of one side of a welding line of the conductor component to be tested, applying thrust to the other side, and testing a second test current value of each group of test points when the thrust is applied, wherein the application direction of the thrust is perpendicular to the extending direction of the welding line; determining a welding deformation resistance score according to the first test current value and the second test current value; determining the welding quality condition of the conductor parts in the current processing batch according to the welding deformation resistance score, the welding appearance score and the quantity ratio of the conductor parts to be detected to the sample conductor parts;
determining a welding appearance score according to the first distance corresponding to the first sampling point and the position coordinate corresponding to the second sampling point, including: determining a first distance mean value and a first distance standard deviation of first distances corresponding to a plurality of first sampling points of a plurality of conductor components to be tested; obtaining the welding seam height appearance scores of the conductor components to be tested according to the first distance average value, the first distance standard deviation and the first distances corresponding to the first sampling points of the conductor components to be tested; fitting according to position coordinates corresponding to second sampling points on the weld edges of all the conductor components to be tested, and obtaining curves of the weld edges; obtaining the minimum distance between the position coordinate corresponding to the second sampling point and the curve of the welding seam edge; determining the appearance scores of the welding seam edges of all the conductor components to be tested according to the minimum distance; determining the welding seam appearance scores of all the conductor components to be tested according to the welding seam height appearance scores and the welding seam edge appearance scores;
Obtaining a welding seam height appearance score of each conductor component to be tested according to the first distance mean value, the first distance standard deviation and the first distances corresponding to the first sampling points of the conductor components to be tested, wherein the welding seam height appearance score comprises the following steps: according to the formula Obtaining a weld height appearance score for the s-th to-be-tested conductor componentWherein, the method comprises the steps of, wherein,For a first distance corresponding to a kth first sampling point on the weld joint of an s-th conductor component to be tested,As a result of the first distance mean,As a result of the first distance standard deviation,In order to be a preset multiple of the number,For the number of the first sampling points on the welding line of the s-th conductor component to be tested, k is less than or equal toAnd k andAll are positive integers, if is a conditional function, max is a maximum function, and min is a minimum function;
determining a weld edge appearance score of each conductor component to be tested according to the minimum distance, including: according to the formula Determining weld edge appearance score for the s-th to-be-tested conductor partWherein, the method comprises the steps of, wherein,For the minimum distance between the t second sampling point on the weld edge of the s-th conductor component to be tested and the curve of the weld edge,In order to preset the distance threshold value,T is less than or equal to the number of second sampling points on the weld edge of the s-th conductor component to be testedAnd t andAre all positive integers;
Determining a weld deformation resistance score from the first and second test current values, comprising: according to the formula Determining a coefficient equation to be determined, wherein,For the force of the x-th applied thrust,In order for the voltage to be a preset value,For a first test current value between the j-th set of test points of the s-th conductor component to be tested,When thrust is applied for the xth time, a second test current value between the j-th group of test points of the s-th conductor component to be tested, n is the group number of the test points, j is less than or equal to n, and s, j and n are positive integers,The coefficient is the undetermined coefficient corresponding to the s-th conductor component to be tested; in the process of repeatedly applying the thrust, obtaining the strength of repeatedly applying the thrust and a second test current value; solving the undetermined coefficient through the force of applying the thrust for a plurality of times and a second test current value to obtain a solution value of the undetermined coefficient; according to the formulaDetermination of weld deformation resistance score for the s-th to-be-tested conductor partWherein, the method comprises the steps of, wherein,Is thatIs used to solve the problem of the (c) for the (c),Is a preset resistance change coefficient.
2. The method of detecting welding quality according to claim 1, wherein screening the sample conductor member according to the first test current value and the reference current value to obtain a plurality of conductor members to be detected, comprises: according to the formulaObtaining a screening score for an ith sample conductor partWherein, the method comprises the steps of, wherein,In order for the voltage to be a preset value,For a first test current value between the j-th set of test points of the i-th sample conductor member,N is the number of groups of test points, max is a maximum value taking function, j is less than or equal to n, and i, j and n are positive integers; and determining the sample conductor part with the screening score higher than or equal to the preset screening threshold value as the conductor part to be tested.
3. The method of claim 1, wherein determining the weld quality status of the current process lot of conductor parts based on the weld distortion resistance score, the weld appearance score, and the quantitative ratio of the to-be-measured conductor parts to the sample conductor parts comprises: according to the formulaA welding quality condition score Q for the conductor component of the current process lot is determined, wherein,Scoring the welding appearance of the s-th conductor part to be tested,Scoring the welding deformation resistance of the s-th conductor part to be measured, wherein p is the number ratio of the conductor part to be measured to the sample conductor part,AndAnd m is the number of the conductor components to be detected, s is less than or equal to m, and s and m are positive integers.
4. A weld quality detection system for performing the method of any of claims 1-3, comprising: the sample conductor component module is used for sampling the conductor components welded in the current processing batch to obtain a plurality of sample conductor components; the first test current value module is used for arranging a plurality of groups of test points on two sides of a welding seam of the sample conductor component, respectively applying preset voltage to each group of test points to obtain a first test current value between each group of test points, and applying the preset voltage between any two test points on the same side of the welding seam to obtain a reference current value of the sample conductor component; the conductor component module to be tested is used for screening the sample conductor components according to the first test current value and the reference current value to obtain a plurality of conductor components to be tested; the device comprises a first sampling point module, a first sampling point module and a second sampling point module, wherein the first sampling points are arranged on a welding line of a conductor component to be tested, the conductor component to be tested is placed on a test bench, at least one section of the welding line is parallel to the plane of the test bench, a laser range finder is arranged right above the test bench, a laser probe of the laser range finder can translate in a first plane parallel to the plane of the test bench, and laser emitted by the laser probe is perpendicular to the plane of the test bench; the first distance module is used for measuring a first distance of a first sampling point in a section of welding line parallel to the plane of the test bench through the laser range finder; the position coordinate module is used for setting a plurality of second sampling points on the edge of the welding seam of the conductor component to be detected, enabling the laser probe of the laser range finder to translate, enabling laser emitted by the laser probe to irradiate to the second sampling points, and obtaining position coordinates of the laser probe in the first plane; the welding appearance scoring module is used for determining welding appearance scoring according to the first distance corresponding to the first sampling point and the position coordinate corresponding to the second sampling point; the second test current value module is used for fixing a part of one side of the welding line of the conductor component to be tested, applying thrust to the other side, and testing a second test current value of each group of test points when the thrust is applied, wherein the application direction of the thrust is perpendicular to the extending direction of the welding line; the welding deformation resistance scoring module is used for determining welding deformation resistance scores according to the first test current value and the second test current value; and the welding quality condition module is used for determining the welding quality condition of the conductor parts of the current processing batch according to the welding deformation resistance score, the welding appearance score and the quantity ratio of the conductor parts to be tested to the sample conductor parts.
5. A welding quality detection device, comprising: a processor; a memory for storing processor-executable instructions; wherein the processor is configured to invoke the instructions stored in the memory to perform the method of any of claims 1-3.
6. A computer readable storage medium, having stored thereon computer program instructions which, when executed by a processor, implement the method of any of claims 1-3.
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