An information-based welding management control system and control method

Abstract

The present invention discloses an information-based welding management control system and control method, the welding management control system includes one or more welding equipment arranged in a welding workshop and a welding monitoring system connected to the welding equipment in communication, the welding equipment includes a welding machine power supply, a welding machine, a gateway server, and a data acquisition system and a welding signal controller embedded in the welding machine, the welding machine power supply is electrically connected to the welding machine and the data acquisition system and welding signal controller embedded in the welding machine, the gateway server and the data acquisition system are electrically connected to the welding signal controller respectively, and the gateway server is connected to the welding monitoring system in communication to realize welding process information management and control. The present invention can not only control and manage the welding equipment, but also monitor the operating status of the welding equipment, thereby improving the automation level and management level of the welding workshop and improving the welding quality control of the product.

Description

Technical Field

[0001] The invention belongs to the technical field of welding management and control, and in particular relates to an information-based welding management control system and a control method. Background Art

[0002] With the rapid development of network technology and information technology, the traditional manufacturing industry and manufacturing technology have undergone revolutionary changes. The digitization and informatization of the welding manufacturing process has become the development trend of the current welding manufacturing industry. Welding workers are increasingly aware that computer information technology will have an important impact on the traditional welding manufacturing process. At present, the management of welding processes in various processing and production workshops is relatively extensive, and welding operations are mostly based on paper operation specifications or welder experience. Managers mainly assess whether operators are operating in a standardized manner through on-site inspections, camera monitoring, and quality inspections of finished welding products. At the same time, since some parameter power adjustments are required during the welding process, they are all manually adjusted, which has certain limitations. Summary of the invention

[0003] The purpose of the present invention is to provide an information-based welding management control system and control method. The control system and control method according to the present invention can not only control and manage welding equipment, but also monitor the operating status of welding equipment, thereby improving the automation level and management level of welding workshops and improving product welding quality control. In order to achieve the above purpose, the present invention adopts the following technical solutions:

[0004] According to one aspect of the present invention, an information-based welding management and control system is provided, characterized in that it includes one or more welding equipment arranged in a welding workshop and a welding monitoring system communicatively connected to the welding equipment, the welding equipment includes a welding power supply, a welding machine, a gateway server, and a data acquisition system and a welding signal controller embedded in the welding machine, the welding power supply is electrically connected to the welding machine and the data acquisition system and the welding signal controller embedded in the welding machine, the gateway server and the data acquisition system are electrically connected to the welding signal controller respectively, and the gateway server is communicatively connected to the welding monitoring system.

[0005] The above scheme is further preferred, wherein the welding monitoring system includes a group control server, a cloud server, a client access terminal, a user access terminal and a field server arranged near the welding workshop, wherein the group control server is wirelessly connected to the gateway server via a wireless transceiver terminal, and the group control server is network-communicated with the cloud server, the client access terminal and the user access terminal respectively via the field server.

[0006] The above scheme is further preferred, wherein the wireless transceiver terminal uses a Zigbee wireless transceiver terminal or a WiFi wireless transceiver terminal for wireless communication.

[0007] The above scheme is further preferred, wherein the data acquisition system includes an image collector, a sound generator, an infrared sensor, a current sensor, a voltage sensor and an RFID radio frequency sensor, and the image collector, the sound generator, the infrared sensor, the current sensor, the voltage sensor and the RFID radio frequency sensor are respectively connected to the welding signal controller.

[0008] The above solution is further preferred that the gateway server is electrically communicated with the welding signal controller via a power carrier.

[0009] The above solution is further preferred that the plurality of welding devices use a bus to perform communication control on the welding machine.

[0010] According to another aspect of the present invention, an information-based welding management and control method is provided, wherein at least one or more welding equipment and a welding monitoring system communicatively connected to the welding equipment are provided in a welding workshop, welding operations are performed through the welding equipment, and welding parameters of the welding site are collected during the welding process; the welding monitoring system acquires welding parameters and is used to monitor changes in the working state of the welding equipment during the welding process, so as to realize management and control of welding process information.

[0011] The above scheme is further preferred, that the welding monitoring system is also equipped with at least a group control server, a cloud server, a client access terminal, a user access terminal and a field server arranged near the welding workshop, and the group control server is equipped with at least one equipment management unit, a user system management unit, a production management unit, a welding data management unit, a welding process management unit and a welding quality management unit for the welding equipment to realize welding process information management and control.

[0012] The above scheme is further preferred, in which the user accesses the terminal to upload the welding order to the user system management unit to generate the welding task and its corresponding welding target; the customer accesses the terminal to formulate the welding process specification and issue the welding task according to the welding task and its corresponding welding target; the welding worker and the welding equipment are identified through the production management unit, and the customer accesses the terminal to access the equipment management unit to select the corresponding welding equipment to perform the welding operation; the welding data management unit obtains the monitoring and collection of the welding operation of the welder and the welding parameters of the welding equipment at the welding site; the welding process management unit obtains the welding parameters and manages and controls the welding process, and sends the welding parameters during the welding operation to the welding quality management unit to generate a welding data report and upload and save the welding data report.

[0013] The above scheme is further preferred, wherein the production management unit includes welder information, welding material information, workpiece information and workshop information; and the welding data management unit includes welder working hour statistics, welding material consumption statistics, energy consumption statistics and welding equipment operation status statistics.

[0014] The present invention adopts the above technical solution, and the present invention has the following technical effects:

[0015] The welding control management system according to the present invention can monitor the welding operation of the welding workshop in real time and remotely monitor the on-site welding data in real time. The welding system of the present invention has simple networking and convenient maintenance. The manager can adjust the welding parameters at any time according to the needs of the site, thereby improving the automation and management level of the welding workshop and improving the control of product welding quality, preventing welding workers from setting welding machine parameters incorrectly, and ensuring the process quality of welding products, thereby realizing a close combination of management and on-site control.

[0016] The present invention realizes real-time monitoring of welding machine status, online monitoring and control of welding parameters, massive storage of welding data, and statistics and analysis of welding data. Through the group control server, the controllability of welding parameters, traceability of welding quality and statistics of welding material consumption can be achieved, thereby improving the production management level of welding construction. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a principle diagram of an information-based welding management and control system of the present invention;

[0018] Figure 2 is a control principle diagram of the welding equipment of the present invention;

[0019] Figure 3 It is a system principle diagram of the group control server of the present invention. DETAILED DESCRIPTION

[0020] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and preferred embodiments. However, it should be noted that many details listed in the specification are only for the purpose of enabling the reader to have a thorough understanding of one or more aspects of the present invention, and these aspects of the present invention can be implemented even without these specific details.

[0021] like Figure 1 and Figure 2As shown, an information-based welding management and control system according to the present invention includes one or more welding equipment arranged in a welding workshop and a welding monitoring system communicatively connected to the welding equipment, wherein the welding equipment includes a welding power supply, a welding machine, a gateway server, and a data acquisition system and a welding signal controller embedded in the welding machine, the welding power supply is electrically connected to the welding machine and the data acquisition system and the welding signal controller embedded in the welding machine, the gateway server and the data acquisition system are electrically connected to the welding signal controller respectively, the gateway server is communicatively connected to the welding monitoring system, and the welding signal controller adopts an STM32F103VET6 single-chip microcomputer control chip. In the present invention, the welding monitoring system includes a group control server, a cloud server, a client access terminal, a user access terminal and a field server arranged near the welding workshop. The group control server is wirelessly connected to the gateway server through a wireless transceiver terminal. The group control server is network-connected to the cloud server, the client access terminal and the user access terminal through the field server. The welding machine power supply is wirelessly connected to the client access terminal through a wireless communication module. The field server is network-connected to the cloud server through a TCP / IP network. The wireless transceiver terminal uses a Zigbee wireless transceiver terminal or a WiFi wireless transceiver terminal for wireless communication. The connection between the electric welder and the group control server is realized by adopting various wireless communication methods such as Zigbee and WiFi. The group control server can be connected to the factory / enterprise LAN, collect the electric welder data and save it locally, and upload the data to the cloud server on the Internet. The manager can access and control the group control server through the customer access terminal (PC or mobile terminal). The manager can also adjust the welding parameters at any time according to the needs of the site, so as to manage and control the electric welders in different workshops. The user can also obtain the data and information of the electric welder from the cloud server on the Internet through the user access terminal (mobile terminal). The manager can request the current power supply welding parameter information from the welding power supply through the customer access terminal; the welding parameter information includes but is not limited to welding current, welding voltage and welding power, and the welding power supply sends the welding parameter information to be currently welded to the customer access terminal according to the request.

[0022] In the present invention, the data acquisition system includes an image collector, a sound generator, an infrared sensor, a current sensor, a voltage sensor and an RFID radio frequency sensor, the image collector, the sound generator, the infrared sensor, the current sensor, the voltage sensor and the RFID radio frequency sensor are respectively connected to the welding signal controller, the gateway server is electrically connected to the welding signal controller through a power carrier, and the plurality of welding devices use a bus to control the communication of the welding machine. The data acquisition system is respectively embedded in the welding machine, wherein the current sensor and the voltage sensor respectively collect the current and voltage signals in the welding process and transmit them to the welding signal controller, which is used to monitor the changes in the working state of the welding machine during the welding process, and dynamically analyze the welding parameters such as peak current, peak voltage or power during the welding process, record them in real time and send them to the welding signal controller for storage and upload them to the group control server for remote transmission and monitoring, adjust the welding parameters according to the detected current and voltage signals to improve the quality of the finished welding product, and the image collector collects the real-time working conditions of the welding workshop and welding and the working conditions of the welding personnel, whether the welding operation is carried out in accordance with the safety regulations, and check the welding through the graphic collector The quality of the finished product, such as whether each welder wears a safety helmet as required, whether the safety helmet position information and posture information are correct, etc.; RFID radio frequency sensor: each welder wears a fixed safety helmet, and RFID radio frequency sensor is used to sense and store the identity information of each welder, the welding machine equipment ID number and the welder information associated with each welding machine equipment; infrared sensor is used to monitor the flow of personnel around the welding machine to prevent people around the welding machine from being exposed to arc radiation. When other non-welding personnel enter the welding area, the sound sending device is activated to give an alarm prompt. The remote terminal monitoring device remotely monitors the on-site welding data in real time, thereby improving the automation and management level of the welding workshop and improving the welding quality control of the product.

[0023] According to another aspect of the present invention, a method for welding management and control is performed using an information-based welding management and control system, combined with Figure 1 and Figure 3As shown, at least one or more welding equipment and a welding monitoring system that is communicatively connected to the welding equipment are provided in the welding workshop, welding operations are performed through the welding equipment, and welding parameters of the welding site are collected during the welding process; the welding monitoring system realizes the acquisition of welding parameters and is used to monitor the changes in the working state of the welding equipment during the welding process, so as to realize the management and control of welding process information. The welding monitoring system is also equipped with at least a group control server, a cloud server, a client access terminal, a user access terminal and a field server arranged near the welding workshop, and the group control server is equipped with at least one equipment management unit, a user system management unit, a production management unit, a welding data management unit, a welding process management unit and a welding quality management unit for the welding equipment, so as to realize the management and control of welding process information; the production management unit includes welder information, welding material information, workpiece information and workshop information; the welding data management unit includes welder working hours statistics, welding material consumption statistics, energy consumption statistics and welding equipment operation status statistics. In the present invention, the method of welding management and control includes the following steps:

[0024] Step S1: The user accesses the terminal to upload the welding order to the user system management unit to generate the welding task and its corresponding welding target; the customer accesses the terminal and issues the welding task according to the welding task and its corresponding welding target and welding process specification; the user system management unit generates the welding task according to the welding order and the formulated process instruction. and Welding parameters: After the customer visits the terminal to confirm the instructions, the welding task is issued. The production management unit refers to the welding workers and welding equipment, which prevents the welding workers from setting the welding machine parameters incorrectly, thus ensuring the process quality of the welding products;

[0025] Step S2: Identify the welding workers and welding equipment through the production management unit; store the RFID radio frequency sensor and upload the identity information of each welder, the welding machine equipment ID number and the welder information associated with each welding machine equipment, so as to prepare for the statistical analysis of the welder attendance, workload data, welding working time and welding material consumption of the welder, and the customer access terminal accesses the equipment management unit to select the corresponding welding equipment for welding operation; for example, request the current power supply welding parameter information from the welding machine power supply; the welding parameter information includes but is not limited to welding current, welding voltage and welding power, and the welding machine power supply sends the welding parameter information to be currently welded to the customer access terminal according to the request;

[0026] Step S3: The welding data management unit obtains, monitors and collects the welding operations of the welders and the welding parameters of the welding equipment at the welding site; the parameters mainly include statistics of all welders' working hours, welding material consumption statistics (monthly consumption of welding wire and gas wire), energy consumption statistics, and welding equipment operation statistics (operation time each month, etc.);

[0027] Step S4: The welding process management unit obtains welding parameters and manages and controls the welding process, and sends the welding parameters in the welding operation process to the welding quality management unit to generate a welding data report and upload and save the welding data report, and classifies and archives the welder identity information, welding machine equipment ID, and welder information and makes a welding data report for uploading and saving; the welding process management unit formulates welding process specifications and process guidance opinions for the obtained welding parameters and queries the historical welding data and evaluates the welding quality. The welding process specifications include pre-flow time, rise time, electric welding time and burn-down time, thermal current size, peak current, pulse current, burner current, initial current, base current, pulse frequency and lagging airflow, etc.

[0028] In the present invention, the welding parameters include a current sensor and a voltage sensor respectively collecting current and voltage signals during the welding process, which are used to monitor the changes in the working state of the electric welder during the welding process, and a dynamic analysis of the welding parameters such as peak current, peak voltage or power during the welding process, which are recorded in real time during the welding process and sent to the welding signal controller for storage and uploaded to the group control server for remote transmission and monitoring, and the welding parameters are adjusted according to the detected current and voltage signals to improve the quality of the finished welding product, and the image collector collects the real-time working conditions of the welding workshop and the welding and the working conditions of the welding personnel, whether the welding operation is performed in accordance with the safety specifications, and the image collector is used to check the welding product. Quality, such as whether each welder wears a helmet as required, whether the helmet position information and posture information are correct, etc.; and RFID radio frequency sensors. Each welder wears a fixed helmet, and the RFID radio frequency sensor senses and stores the identity information of each welder, the welding machine equipment ID number and the welder information associated with each welding machine equipment; and infrared sensors are used to monitor the flow of personnel around the welding machine to prevent the personnel around the welding machine from being exposed to arc radiation. When other non-welding personnel enter the welding area, the sound sending device is activated to alarm, and the remote terminal monitoring device remotely monitors the on-site welding data in real time, thereby improving the automation and management level of the welding workshop and improving the welding quality control of the product. The welding parameters include not only the welding current and voltage, but also the welding speed, ambient temperature, welder, welding material, welding start time, welding end time, post-welding cooling time, and non-destructive testing after welding.

[0029] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. An information-based welding management and control system, characterized in that: The welding management and control system includes one or more welding devices arranged in a welding workshop and a welding monitoring system communicatively connected to the welding devices, wherein the welding devices include a welding power supply, a welding machine, a gateway server, and a data acquisition system and a welding signal controller embedded in the welding machine, wherein the welding power supply is electrically connected to the welding machine and the data acquisition system and the welding signal controller embedded in the welding machine, wherein the gateway server and the data acquisition system are electrically connected to the welding signal controller respectively, and wherein the gateway server is communicatively connected to the welding monitoring system; The welding monitoring system includes a group control server, a cloud server, a client access terminal, a user access terminal and a field server arranged near the welding workshop. The group control server is connected to the gateway server by wireless communication through a wireless transceiver terminal, and the group control server is connected to the cloud server, the client access terminal and the user access terminal by network communication through the field server; the group control server is equipped with at least one equipment management unit, a user system management unit, a production management unit, a welding data management unit, a welding process management unit and a welding quality management unit for the welding equipment to realize the management and control of the welding process information; the data acquisition system includes an image collector, a sound generator, an infrared sensor, a current sensor, a voltage sensor and an RFID radio frequency sensor, and the image collector, the sound generator, the infrared sensor, the current sensor, the voltage sensor and the RFID radio frequency sensor are connected to the welding signal controller respectively; The welding control method is as follows: at least one or more welding equipment and a welding monitoring system in communication with the welding equipment are provided in a welding workshop, welding operations are performed through the welding equipment, and welding parameters of the welding site are collected during the welding process; the welding monitoring system acquires welding parameters and is used to monitor changes in the working state of the welding equipment during the welding process, so as to realize management and control of welding process information; The user accesses the terminal to upload the welding order to the user system management unit to generate the welding task and its corresponding welding target; the customer accesses the terminal to formulate the welding process specification and issue the welding task according to the welding task and its corresponding welding target; the user system management unit issues the welding task according to the welding order and the formulated process guidance and welding parameters after the customer accesses the terminal to confirm the instruction; the production management unit controls the welding workers and welding equipment to prevent the welding workers from setting the welding machine parameters incorrectly, thus ensuring the process quality of the welding products; The production management unit identifies the welding workers and welding equipment, and the customer accesses the terminal to access the equipment management unit to select the corresponding welding equipment for welding operation; the production management unit stores the identity information of each welder, the welding machine equipment ID number and the welder information associated with each welding machine equipment sensed and uploaded by the RFID radio frequency sensor, and prepares for the statistical analysis of the welder attendance, workload data, welding working time and welding material consumption of the welders; The welding parameter information includes welding current, welding voltage and welding power, and the welding machine power supply sends the welding parameter information of the current welding to be performed to the customer access terminal according to the request; The welding data management unit acquires, monitors and collects welding operations of welding personnel and welding parameters of welding equipment at the welding site; The welding process management unit acquires welding parameters and manages and controls the welding process, sends the welding parameters during the welding operation to the welding quality management unit to generate a welding data report, and uploads and saves the welding data report.

2. The information-based welding management and control system according to claim 1 is characterized in that: The wireless transceiver terminal uses a Zigbee wireless transceiver terminal or a WiFi wireless transceiver terminal for wireless communication.

3. The information-based welding management and control system according to claim 1 is characterized in that: The gateway server is electrically connected to the welding signal controller via a power carrier.

4. The information-based welding management and control system according to claim 1 is characterized in that: The plurality of welding devices use a bus to perform communication control on the welding machine.

5. The information-based welding management and control system according to claim 1 is characterized in that: The production management unit includes welder information, welding material information, workpiece information and workshop information; the welding data management unit includes welder working hour statistics, welding material consumption statistics, energy consumption statistics and welding equipment operation status statistics.

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