CN-121979081-A - High-precision resistance spot welding equipment for monitoring coordinated control

CN121979081ACN 121979081 ACN121979081 ACN 121979081ACN-121979081-A

Abstract

The invention discloses high-precision resistance spot welding equipment for monitoring coordinated control, which relates to the technical field of resistance spot welding, and comprises a main control circuit board, an integrated power module, an IGBT driving module, an ADC analog signal processing unit, a communication interface and a digital I/O isolation driving module, wherein the main control circuit board takes a TDA4VM chip as a control core, the modules and the units are in electric signal connection with the main control circuit board, the TDA4VM chip controls an inversion direct current welding power supply of a spot welding machine through the IGBT driving module, receives signals of a sensor system through the ADC analog signal processing unit, interacts with a visual monitoring unit and external equipment through a communication interface and realizes safe control and actuator driving through digital I/O isolation driving.

Inventors

LI YI
GAO YUZENG
LI XIANG
Rong Zichang
DENG BOXIN
LI YUANQI
YIN LI

Assignees

湘潭大学

Dates

Publication Date: 20260505
Application Date: 20260409

Claims (5)

1. The high-precision resistance spot welding equipment for monitoring coordinated control is characterized by comprising a spot welding machine, a sensor unit, a data acquisition and processing unit, a visual monitoring unit, a clamp, a positioning mechanism and a main control circuit board; The main control circuit board takes a TDA4VM chip as a control core and comprises an integrated power supply module, an IGBT driving module, an ADC analog signal processing unit, a communication interface and a digital I/O isolation driving module, wherein each module and each unit are connected with the main control circuit board through electric signals; The TDA4VM chip controls an inversion direct current welding power supply of the spot welder through the IGBT driving module, receives signals of a sensor system through the ADC analog signal processing unit, interacts with the visual monitoring unit and external equipment through a communication interface, realizes safe control and actuator driving through digital I/O isolation driving, and the external equipment comprises a display screen integrated controller with a control function.
2. The high-precision resistance spot welding equipment for monitoring and coordinated control according to claim 1, wherein the spot welding machine comprises a frame support, a pressurizing device is fixed on the frame support, an upper electrode and a lower electrode are arranged on one side of the pressurizing device, the high-precision resistance spot welding equipment further comprises a high-frequency transformer, the high-frequency transformer is electrically connected with the display screen integrated controller, the upper electrode is connected with the negative electrode end of the high-frequency transformer, and the lower electrode is connected with the positive electrode end of the high-frequency transformer.
3. The high-precision resistance spot welding equipment for monitoring coordinated control according to claim 2, wherein the sensor system comprises a rogowski coil sleeved on a lower electrode cable, an eddy current displacement sensor laser displacement sensor arranged near an upper electrode, a voltage acquisition circuit for acquiring voltage between electrodes through an isolation amplifying circuit and a temperature sensor, and each sensor signal is input into an ADC analog signal processing unit after being subjected to an isolation power supply.
4. The high-precision resistance spot welding device for monitoring coordinated control according to claim 1, wherein the visual monitoring unit adopts AcutEye high-speed cameras, is connected with a TDA4VM chip through a network interface, receives a synchronous trigger signal, and realizes synchronous analysis of an electric signal and a visual signal.
5. The high-precision resistance spot welding equipment for monitoring coordinated control according to claim 1, wherein the clamp and positioning device comprises a 3D printing clamp for fixing an eddy current sensor and a precision positioning table, the TDA4VM chip controls the position of the positioning table through a solenoid valve output signal driven by digital I/O isolation, and closed-loop control with assembly precision less than or equal to 0.05mm is realized by combining a feedback signal of a laser displacement sensor of the eddy current displacement sensor.

Description

High-precision resistance spot welding equipment for monitoring coordinated control Technical Field The invention belongs to the technical field of resistance spot welding, and particularly relates to high-precision resistance spot welding equipment for monitoring coordinated control. Background Micro parts (thickness about 0.3 mm) such as aviation relay reeds are often connected by resistance spot welding. Because the part size is small, the electrode shape is asymmetric (the upper electrode is conical, the lower electrode is a backing plate), the problems of splashing, unstable welding core size, difficult post-welding detection and the like are easy to occur in the welding process. The traditional method adopts post-welding destructive tests (such as stretching and stripping) or ultrasonic detection, has low efficiency and high cost, and cannot realize real-time monitoring and process closed-loop control of the welding process. At present, although some resistance spot welding monitoring systems exist, the problems of low signal acquisition precision, difficult sensor installation, poor anti-interference capability and the like exist in the welding of tiny parts aiming at the conventional plate thickness welding. In addition, the process parameters are set empirically, and a system optimization method based on simulation and data analysis is lacked. Disclosure of Invention Aiming at the problems of serious energy storage welding splashing and insufficient fine medium-frequency inverter welding control in the prior art, the invention provides resistance spot welding equipment integrated with a real-time monitoring system, which realizes multi-signal real-time monitoring, intelligent optimization of technological parameters and post-welding quality prediction in the welding process and is particularly suitable for precision welding of tiny parts such as aviation relay reeds and the like. In order to achieve the above purpose, the present invention provides the following technical solutions: A high-precision resistance spot welding device for monitoring coordinated control comprises a spot welder, a sensor unit, a data acquisition and processing unit, a visual monitoring unit, a clamp, a positioning mechanism and a main control circuit board; The main control circuit board takes a TDA4VM chip as a control core and comprises an integrated power supply module, an IGBT driving module, an ADC analog signal processing unit, a communication interface and a digital I/O isolation driving module, wherein each module and each unit are connected with the main control circuit board through electric signals; The TDA4VM chip controls an inversion direct current welding power supply of the spot welder through the IGBT driving module, receives signals of a sensor system through the ADC analog signal processing unit, interacts with the visual monitoring unit and external equipment through a communication interface, realizes safe control and actuator driving through digital I/O isolation driving, and the external equipment comprises a display screen integrated controller with a control function. Further, the spot welder comprises a frame support column, a pressurizing device is fixed on the frame support column, an upper electrode and a lower electrode are arranged on one side of the pressurizing device, the spot welder further comprises a high-frequency transformer, the high-frequency transformer is electrically connected with the display screen integrated controller, the upper electrode is connected with the negative electrode end of the high-frequency transformer, and the lower electrode is connected with the positive electrode end of the high-frequency transformer. Further, the sensor system comprises a rogowski coil sleeved on a lower electrode cable, a laser displacement sensor arranged near an upper electrode, a voltage acquisition circuit for acquiring the voltage between electrodes through an isolation amplifying circuit, and a temperature sensor, wherein each sensor signal is input into an ADC analog signal processing unit after passing through an isolation power supply. Furthermore, the visual monitoring unit adopts AcutEye high-speed cameras, is connected with the TDA4VM chip through a network interface, receives a synchronous trigger signal, and realizes synchronous analysis of the electric signals and the visual signals. Further, the fixture and positioning device comprises a 3D printing fixture for fixing the eddy current sensor and a precise positioning table, the TDA4VM chip controls the position of the positioning table through a solenoid valve output signal driven by digital I/O isolation, and closed-loop control with the assembly precision less than or equal to 0.05mm is realized by combining a feedback signal of the laser displacement sensor. In summary, the beneficial technical effects of the invention are as follows: 1. The device realizes full-dimensional real-time monitoring of welding current, elect