Spot Welding Electrode Detection System Based On Muti-sensor Data Fusion

With the rapid development of modern industrial production,the application of robot welding clamp equipment in the aerospace and automotive industries is becoming more and more extensive,and its role is pivotal.To ensure the efficient and high-quality welding of aerospace and automotive manufacturing industries,the realization of "Zero defective" and "zero defect" product management goals,many enterprises have focused more on the guarantee of equipment performance,on the basis of ensuring the safe,stable,reliable and long-term operation of robot workstations,there is an urgent need Information feedback system based on process parameters to evaluate the health status of robot welding tongs and complete its performance testing,continuously optimize the online analysis of equipment status and establish a mathematical model based on health index,using advanced technology equipment and scientific and reasonable evaluation methods Improve the operation status detection and comprehensive performance evaluation system of the equipment to ensure that the robot welding clamp equipment can operate stably and efficiently and deal with sudden failures in a timely manner.This is not only related to the economic benefits of the enterprise,but also closely related to the personal safety of the staff.The paper starts with the design and construction of a multi-sensor welding jaw testing system using information technology and sensor technology as the platform to address the problems of leak detection,omission and poor traceability in the dispersed item-by-item inspection of robotic welding jaw equipment,and realized the PLC control network of the test system Configuration and design based on multi-sensor test module.Secondly,in order to solve the problem of insufficient precision control in servo welding clamp tracking control and load adjustment control in the inspection system,the servo driver and welding controller were designed respectively,and a small response force to the electrode tip and a fast response speed to pressure change and servo spot welding system with precise control of motor pressure,displacement and speed.Thirdly,in order to solve the problem that the precision and fastness of conventional PID control system are reduced due to the strong coupling between water flow and pressure during the test process of welding clamps,an analysis of the coupling relationship between flow and pressure and the ID3 algorithm of a decision tree are used to design a The fuzzy PID decoupling control system with the opening degree of the control valve as the main flow control amount and the frequency converter as the main pressure control amount was tested.The dynamic and static performance of the control system was tested based on the flow rate and pressure sensors.Finally,the host computer monitoring system was developed,and based on the data collected by the robot welding tongs equipment at multiple angles and multiple channels,the Bayesian decision was used to classify the welding tongs test historical data to verify the robot welding tongs performance evaluation method.