A device and method for detecting the wire feeding speed of a welding wire

Abstract

The present invention discloses a device and method for detecting the wire feeding speed of a welding wire, including a welding wire. The welding wire is connected to a welding torch after passing between a driving wheel and a driven wheel. The driving wheel is driven by a motor to rotate. A regular polygon nut is installed at the center position on the side of the driving wheel away from the motor. At least one side of the regular polygon nut is provided with a pulse signal timing system. When the motor drives the regular polygon nut to rotate, at least one side of the side surface of the polygon nut will trigger the pulse signal timing system to start timing. The pulse signal timing system is used to time the time interval between the sides of the regular polygon nut that can trigger the pulse signal timing system rotating to the corresponding positions in sequence. The present invention ingeniously replaces the time taken for the driving wheel to rotate a certain arc with the time taken for the polygon nut to rotate a certain arc, thereby obtaining the time taken for the driving wheel to rotate a certain arc, and conveniently calculating the wire feeding speed of the welding wire.

Description

Technical Field

[0001] The present invention belongs to the technical field of wire feeding speed detection for welding wires, and particularly relates to a device and method for detecting the wire feeding speed of welding wires. Background Art

[0002] With the improvement of modern welding technology and robot technology, welding robots are becoming more and more mature. The speed of wire feeding will affect the welding quality. Therefore, it is often necessary to detect and control the speed of wire feeding. In the past, it was judged whether the feeding speed was appropriate based on experience or the actual feeding effect, which belonged to post - judgment. Since the wire feeding speed cannot be accurately known, it will cause a mismatch with the subsequent product processing technology, resulting in inconsistent product quality. Summary of the Invention

[0003] The purpose of the present invention is to provide a device and method for detecting the wire feeding speed of welding wires to solve the problems raised in the above background art. To achieve the above purpose, the present invention provides the following technical solutions:

[0004] A device for detecting the wire feeding speed of welding wires includes a welding torch, a driven wheel, a driving wheel, a regular polygon nut, a welding wire and a wire reel. The welding wire provided by the wire reel passes between the driving wheel and the driven wheel and then is connected to the welding torch. The driving wheel is driven by a motor to rotate. A regular polygon nut is installed at the center position of the side of the driving wheel away from the motor. At least one side of the regular polygon nut is provided with a pulse signal timing system. When the motor drives the polygon nut to rotate, at least one side of the side surface of the polygon nut will trigger the pulse signal timing system to start timing. The pulse signal timing system is used to time the time interval between the side surfaces of the regular polygon nut that can trigger the pulse signal timing system rotating to the positions corresponding to the pulse signal timing system in turn.

[0005] A further solution is that a black magnet is installed on one side surface of the regular polygon nut. At least one side of the regular polygon nut is provided with a photoelectric switch. The output of the photoelectric switch is connected to the non - inverting terminal of a comparator. The inverting terminal of the comparator is connected to a potentiometer. The output of the comparator is connected to the input terminal of a single - chip microcomputer. The photoelectric switch, the comparator, the potentiometer and the single - chip microcomputer form a pulse signal timing system.

[0006] A further solution is that a moving electrode plate grounded is installed on one side surface of the regular polygon nut. At least one side of the regular polygon nut is provided with a fixed electrode plate. The fixed electrode plate is fixed relative to the motor. The signal output by the fixed electrode plate is converted into an electrical signal through a measurement circuit and then transmitted to the single - chip microcomputer. The moving electrode plate, the fixed electrode plate, the measurement circuit and the single - chip microcomputer form a pulse signal timing system.

[0007] A further solution is that the pulse signal timing system consists of an ultrasonic sensor and a single-chip microcomputer. The ultrasonic sensor is fixed relative to the motor and its transmitting end faces the polygonal nut.

[0008] A further solution is that the regular polygonal nut is a hexagonal nut.

[0009] A further solution is that the single-chip microcomputer is electrically connected to a display screen. The single-chip microcomputer is of the STC series, and the display screen is of the OLED series.

[0010] A further solution is that the photoelectric switch is adsorbed on the motor by a magnet.

[0011] A further solution is that the fixed electrode plate is adsorbed on the motor by a magnet.

[0012] A further solution is that the measurement circuit includes an AC power supply, a first operational amplifier, and a second operational amplifier. The AC power supply is connected to a capacitor and then to the inverting input terminal of the first operational amplifier. The inverting input terminal of the first operational amplifier is connected to the moving electrode plate. The fixed electrode plate is connected to the output of the first operational amplifier. The output of the first operational amplifier is also connected to the non-inverting input terminal of the second operational amplifier. After comparison, the output is connected to the single-chip microcomputer.

[0013] A method for detecting the wire feeding speed of a welding wire includes the following steps:

[0014] (1) Install a driving wheel on the output end of the motor. The welding wire passes between the driving wheel and the driven wheel and then is connected to the welding torch.

[0015] (2) Install a regular polygonal nut at the center position of the driving wheel.

[0016] (3) Arrange a pulse signal timing system on at least one side of the regular polygonal nut. The pulse signal timing system is fixed relative to the motor. Ensure that during the process of the motor driving the regular polygonal nut to rotate, at least one side of the regular polygonal nut can trigger the pulse signal timing system to work. The pulse signal timing system measures the time interval t between the corresponding sides of the regular polygonal nut rotating to the positions corresponding to the pulse signal timing system in sequence.

[0017] (4) The wire feeding length can be obtained based on the rotation radian and the circumference of the driving wheel, and then the wire feeding speed can be calculated according to the measured time interval.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention is ingeniously designed, easy to install, and highly practical. By tightly pressing the welding wire with the driving wheel and the driven wheel, the feeding length of the welding wire can be approximately equal to the circumference of the rotation of the driving wheel. Then, a regular polygon nut is installed on the driving wheel, so that the time taken for the driving wheel to rotate a certain arc is equal to the time taken for the regular polygon nut to rotate a certain arc. Cleverly, the time taken for the driving wheel to rotate a certain arc is replaced by calculating the time taken for the regular polygon nut to rotate a certain arc; and each side of the regular polygon nut is equal, and the angle of the midpoint of each side relative to the center point of the nut is easy to calculate. During the process of the driving wheel driving the regular polygon nut to rotate, the trigger pulse signal timing system starts timing, so as to obtain the time taken for the regular polygon nut to rotate a certain arc. The time taken for the regular polygon nut to rotate a certain arc is equal to the time taken for the driving wheel to rotate a certain arc, and thus the feeding speed of the welding wire can be easily calculated and displayed on the display screen, the feeding speed is detected in real time, the welding quality is improved, and a solution is provided for welding automation. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 Schematic diagram of the structure of the first embodiment of the present invention;

[0020] Figure 2 Circuit diagram of the first embodiment of the present invention;

[0021] Figure 3 Schematic diagram of the structure of the second embodiment of the present invention;

[0022] Figure 4 Circuit diagram of the second embodiment of the present invention;

[0023] Figure 5 Schematic diagram of the structure of the third embodiment of the present invention;

[0024] Figure 6 Circuit diagram of the third embodiment of the present invention;

[0025] Reference numerals: welding torch (101, 201, 301), DC motor (102, 202, 302), driven wheel (103, 203, 303), driving wheel (104, 204, 304), regular polygon nut (105, 205, 305), welding wire (106, 206, 306), welding wire reel (107, 207, 307), display screen (108, 208, 308), single-chip microcomputer (109, 209, 309), first electromagnet (110), first photoelectric switch (111), black magnet (112), second photoelectric switch (113), second electromagnet (114), first potentiometer (115), first comparator (116), second comparator (117), second potentiometer (118), moving plate (210), measuring circuit (211), fixed plate (212), electromagnet (213), AC power supply (214), capacitance sensor (215), first operational amplifier (216), second operational amplifier (217), wooden frame (310), ultrasonic sensor (311). Detailed implementation manners

[0026] The following will further elaborate on the present invention in conjunction with the attached Figures 1 to 6 drawings.

[0027] First detailed implementation manner

[0028] As Figure 1 shown, it includes a welding torch 101, a driven wheel 103, a driving wheel 104, a regular polygon nut 105, a welding wire 106 and a welding wire reel 107. The welding wire 106 provided by the welding wire reel 107 is connected to the welding torch 101 after passing between the driving wheel 104 and the driven wheel 103. The driving wheel 104 and the driven wheel 103 tightly press the welding wire 106, so that the wire feeding length of the welding wire 106 can be approximately equal to the circumference of the rotation of the driving wheel 104. The driving wheel 104 is driven to rotate by a motor 102. In this embodiment, the motor 102 is a DC motor. The rotation speed of the driving wheel 104 driven by the DC motor changes with the change of the current. A regular polygon nut 105 is installed at the center position on the side of the driving wheel 104 away from the DC motor. The regular polygon nut 105 is silver in color and has good light reflection performance. A black magnet 112 is adsorbed on one side of the regular polygon nut 105. In this embodiment, the regular polygon nut 105 is a hexagonal nut. At least one side of the regular polygon nut 105 is provided with a photoelectric switch. In this embodiment, the number of photoelectric switches is two, which are the first photoelectric switch 111 and the second photoelectric switch 113 respectively. The first photoelectric switch 111 and the second photoelectric switch 113 are symmetrically arranged on both sides of the hexagonal nut, so that the first photoelectric switch 111 and the second photoelectric switch 113 are directly opposite at 180 degrees. The first photoelectric switch 111 and the second photoelectric switch 113 are respectively adsorbed on the DC motor through the first electromagnet 110 and the second electromagnet 114.

[0029] Further, referring to the attached Figure 1 and 2 , the output of the first optoelectronic switch 111 is connected to the non-inverting terminal of the first comparator 116, the inverting terminal of the first comparator 116 is connected to the first potentiometer 115, the output of the second optoelectronic switch 113 is connected to the non-inverting terminal of the second comparator 117, the inverting terminal of the second comparator 117 is connected to the second potentiometer 118, the output of the first comparator 116 is connected to the input port P3.2 pin of the single-chip microcomputer 109, the output of the second comparator 117 is connected to the input port P3.3 pin of the single-chip microcomputer 109, the P3.1 pin and the P3.0 pin of the single-chip microcomputer 109 are respectively connected to the SCL pin and the SDA pin of the display screen 108. In the embodiment, the model of the single-chip microcomputer 109 is STC15F104W, and the display screen 108 is an OLED series display screen. The display screen 108 can be used to display the wire feeding speed, detect the wire feeding speed in real time, and improve the welding quality.

[0030] When the first optoelectronic switch 111 faces the silver hexagon nut, the receiving tube of the first optoelectronic switch 111 receives more light, and a low level can be output through the first comparator 116. When the black magnet 112 reaches the first optoelectronic switch 111, the light received by the receiving tube of the first optoelectronic switch 111 decreases, and a high level is output after passing through the first comparator 116. When the P3.2 pin of the single-chip microcomputer 109 receives the jump from low level to high level, the built-in timer starts timing from 0. Similarly, when the black magnet 112 reaches the second optoelectronic switch 113, the level received by the P3.3 pin of the single-chip microcomputer 109 also changes from low level to high level. When the P3.3 pin of the single-chip microcomputer 109 captures the high level, the timer records the time and starts timing from 0 again, and the time required for the black magnet 112 to rotate from the first optoelectronic switch 111 to the second optoelectronic switch 113 can be obtained, which is t1. Similarly, the time required for the black magnet 112 to rotate from the second optoelectronic switch 113 to the first optoelectronic switch 111 can be obtained, which is t2.

[0031] When the radius of the driving wheel 104 is R and the circumference of rotating half a week is πR, and the time required for the black magnet 112 to move from the first optoelectronic switch 111 to the second optoelectronic switch 113 can be obtained by timing with the single-chip microcomputer 109, which is t1, then the wire feeding speed is v1 = πR / t1; the time required for the black magnet 112 to move from the second optoelectronic switch 113 to the first optoelectronic switch 111 can be obtained through the same operation of the single-chip microcomputer 109, which is t2, and the wire feeding speed can be calculated as v2 = πR / t2. In order to reduce errors, the wire feeding speed can be calculated multiple times and then the average value is obtained. Through the electrical connection between the single-chip microcomputer 109 and the display screen 108, the wire feeding speed of the welding wire can be displayed on the display screen 108, the wire feeding speed can be detected in real time, and the welding quality can be improved.

[0032] The second specific implementation mode

[0033] As Figure 3 shown, it includes a welding torch 201, a driven wheel 203, a driving wheel 204, a regular polygon nut 205, a welding wire 206 and a welding wire reel 207. The welding wire 206 provided by the welding wire reel 207 is connected to the welding torch 201 after passing between the driving wheel 204 and the driven wheel 203. The driving wheel 204 and the driven wheel 203 tightly press the welding wire 206, so that the feeding length of the welding wire 206 can be approximately equal to the circumference of the rotation of the driving wheel 204. The driving wheel 204 is driven by a motor 202 to rotate. In this embodiment, the motor 202 is a DC motor. A regular polygon nut 205 is installed at the center position of the side of the driving wheel 204 away from the DC motor. A moving electrode plate 210 is installed on one side surface of the regular polygon nut 205. In this embodiment, the regular polygon nut 205 is a hexagonal nut. A fixed electrode plate 212 is arranged on one side of the regular polygon nut 205. During the process of the DC motor driving the moving electrode plate 210 to rotate, the moving electrode plate 210 can be parallel to the fixed electrode plate 212, and the fixed electrode plate 212 is adsorbed on the motor by a magnet 213.

[0034] Further, referring to Att Figure 3 and Att Figure 4 , the signal output by the fixed electrode plate 212 is converted into an electrical signal by a measurement circuit 211 and then transmitted to a single-chip microcomputer 202. The moving electrode plate 210, the fixed electrode plate 212, the measurement circuit 211 and the single-chip microcomputer 209 form a pulse signal timing system. The measurement circuit 211 includes an AC power supply 214, a first operational amplifier 216 and a second operational amplifier 217. The AC power supply 214 is connected to the inverting terminal of the first operational amplifier 216 after being connected to a capacitor. The inverting terminal of the first operational amplifier 216 is connected to the moving electrode plate 210. The fixed electrode plate 212 is connected to the output of the first operational amplifier 216. The output of the first operational amplifier 216 is also connected to the non-inverting terminal of the second operational amplifier 217. The digital signal output after comparison is connected to the P3.4 port of the single-chip microcomputer 209. The P3.0, P3.1, P3.2 and P3.3 of the single-chip microcomputer 209 are respectively connected to the DC, RES, D1 and D0 pins of the display screen 208. In this embodiment, the model of the single-chip microcomputer 209 is STC15F101W-35I-SOP8, and the display screen 208 is an OLED series display screen. The data processed by the single-chip microcomputer 209 communicates with the display screen 208 in SPI communication mode.

[0035] When the moving electrode plate 210 fixed on the hexagonal nut rotates to be parallel to the fixed electrode plate 212, after being processed by the measurement circuit 211, a high level is output by the second operational amplifier 217. When the moving electrode plate 210 fixed on the hexagonal nut is not parallel to the fixed electrode plate 212, after being processed by the measurement circuit 211, a low level is output by the second operational amplifier 217. When the P3.4 pin of the single-chip microcomputer 209 receives a jump from low level to high level, the built-in timer 0 is started to count from 0. When receiving a jump from low level to high level again, the timing is stopped, and the timing time is taken as t1. Then the timer starts to count from 0 again, repeating the above operations to obtain the average wire feeding speed, and the wire feeding speed of the welding wire is displayed on the display screen 208 to detect the wire feeding speed in real time and improve the welding quality.

[0036] The Third Specific Embodiment

[0037] As Figure 5 shown, it includes a welding torch 301, a driven wheel 303, a driving wheel 304, a regular polygon nut 305, a welding wire 306 and a welding wire reel 307. The welding wire 306 provided by the welding wire reel 307 is connected to the welding torch 301 after passing between the driving wheel 304 and the driven wheel 303. The driving wheel 304 and the driven wheel 303 tightly press the welding wire 306, so that the wire feeding length of the welding wire 306 can be approximately equal to the circumference of the rotation of the driving wheel 304. The driving wheel 304 is driven by a motor 302 to rotate. In this embodiment, the motor 302 is a DC motor. A regular polygon nut 305 is installed at the center position on the side of the driving wheel 304 away from the DC motor. In this embodiment, the regular polygon nut 305 is a hexagonal nut. An ultrasonic sensor 311 is arranged on one side of the regular polygon nut 305. The ultrasonic sensor 311 is fixed relative to the DC motor and its transmitting end faces the polygon nut 305. During the rotation of the regular polygon nut 305 driven by the DC motor, the side surface of the regular polygon nut 305 can be parallel to the transmitting end of the ultrasonic sensor 311. The ultrasonic sensor 311 is installed on a wooden frame 310, and the wooden frame 310 is installed on the base, and the motor 302 is also installed on the base.

[0038] Further, referring to Appendix Figure 5 and Appendix Figure 6, the ultrasonic sensor 311 and the single-chip microcomputer 302 form a pulse signal timing system. The model of the single-chip microcomputer 302 is STC15F101W-35I-SOP8, and the model of the ultrasonic sensor 311 is US500-G12-N-M12. The output of the ultrasonic sensor 311 is connected to the P3.4 port of the single-chip microcomputer 302. The P3.3 port and P3.2 port of the single-chip microcomputer 302 are respectively connected to the D0 pin and D1 pin of the display screen 308. The RES pin and DC pin of the display screen 308 are respectively connected to the P3.1 pin and P3.0 pin of the single-chip microcomputer 302. The display screen 308 is an OLED series display screen.

[0039] When the side of the hexagonal nut rotates to be parallel to the transmitting end of the ultrasonic sensor 311, the ultrasonic wave emitted by the ultrasonic sensor 311 hits the side of the hexagonal nut parallel to it and can be completely reflected back. At this time, the switching value output by the ultrasonic sensor 311 is low level. When the side of the hexagonal nut is not parallel to the ultrasonic sensor 311, the ultrasonic wave emitted by the ultrasonic sensor 311 cannot be completely reflected back by the hexagonal nut. Then, the switching value output by the ultrasonic sensor 311 at this time is high level; when the P3.4 pin of the single-chip microcomputer 309 receives a jump from high level to low level, the built-in timer of the single-chip microcomputer 309 starts timing from 0 until it receives the next jump from high level to low level, then the timer stops timing, and the timing time t is taken out. Then the frequency of the pulse is f = 1 / t. Then let the timer start timing again until the P3.4 pin of the single-chip microcomputer 309 receives the next jump from high level to low level, and then take out the timing time. By repeating this process, the average wire feeding speed can be calculated and the wire feeding speed of the welding wire is displayed on the display screen 308 to detect the wire feeding speed in real time and improve the welding quality.

[0040] The embodiments of the present invention have been described in detail above in conjunction with the accompanying drawings. However, the present invention is not limited to this. Within the scope of knowledge possessed by those skilled in the art of the said technology, various changes can be made without departing from the purpose of the present invention.

Claims

1. A device for detecting the wire feeding speed of a welding wire, characterized in that: It includes welding torches (101, 201, 301), driven wheels (103, 203, 303), driving wheels (104, 204, 304), regular polygon nuts (105, 205, 305), welding wires (106, 206, 306) and wire spools (107, 207, 307). The welding wires (106, 206, 306) provided by the wire spools (107, 207, 307) are connected to the welding torches (101, 201, 301) after passing between the driving wheels (104, 204, 304) and the driven wheels (103, 203, 303). The driving wheels (104, 204, 304) are driven to rotate by motors (102, 202, 302). At the central position on the side of the driving wheels (104, 204, 304) away from the motors (102, 202, 302), regular polygon nuts (105, 205, 305) are installed. At least one side of the regular polygon nuts (105, 205, 305) is provided with a pulse signal timing system. When the motors (102, 202, 302) drive the regular polygon nuts (105, 205, 305) to rotate, at least one side of the side surface of the regular polygon nuts (105, 205, 305) will trigger the pulse signal timing system to start timing. The pulse signal timing system is used to time the time interval between the side surfaces of the regular polygon nuts (105, 205, 305) that can trigger the pulse signal timing system and rotate to the positions corresponding to the pulse signal timing system in sequence; A moving electrode plate (210) is installed on one side surface of the regular polygon nut (205). At least one side of the regular polygon nut (205) is provided with a fixed electrode plate (212). The fixed electrode plate (212) is fixed relative to the motor (202). The signal output by the fixed electrode plate (212) is converted into an electrical signal by a measurement circuit (211) and then transmitted to a single-chip microcomputer (209). The moving electrode plate (210), the fixed electrode plate (212), the measurement circuit (211) and the single-chip microcomputer (209) form a pulse signal timing system; The measurement circuit (211) includes an AC power supply (214), a first operational amplifier (216) and a second operational amplifier (217). The AC power supply (214) is connected to a capacitor and then connected to the inverting terminal of the first operational amplifier (216). The inverting terminal of the first operational amplifier (216) is connected to the moving electrode plate (210). The fixed electrode plate (212) is connected to the output of the first operational amplifier (216). The output of the first operational amplifier (216) is also connected to the non-inverting terminal of the second operational amplifier (217). After comparison, the output is connected to the single-chip microcomputer (209); A black magnet (112) is installed on one side of the regular polygon nut (105). At least one side of the regular polygon nut (105) is provided with a photoelectric switch. The output of the photoelectric switch is connected to the non-inverting input end of a comparator. The inverting input end of the comparator is connected to a potentiometer. The output of the comparator is connected to the input end of a single-chip microcomputer (109). The photoelectric switch, comparator, potentiometer and single-chip microcomputer (109) form a pulse signal timing system.

2. The device for detecting the wire feeding speed of a welding wire according to claim 1, wherein: The pulse signal timing system consists of an ultrasonic sensor (311) and a single-chip microcomputer (309). The ultrasonic sensor (311) is fixed relative to the motor (302) and the transmitting end faces the regular polygon nut (305).

3. A device for detecting the wire feeding speed of a welding wire according to any one of claims 1-2, characterized in that: The regular polygon nuts (105, 205, 305) are hexagonal nuts.

4. A device for detecting the wire feeding speed of a welding wire according to any one of claims 1-2, characterized in that: The single-chip microcomputers (109, 209, 309) are electrically connected to the display screens (108, 208, 308). The single-chip microcomputers (109, 209, 309) are single-chip microcomputers of the STC series. The display screens (108, 208, 308) are display screens of the OLED series.

5. The device for detecting the wire feeding speed of a welding wire according to claim 1, characterized in that: The photoelectric switch is adsorbed on the motor (102) by a magnet.

6. The device for detecting the wire feeding speed of a welding wire according to claim 1, characterized in that: The fixed pole plate (212) is adsorbed on the motor (202) by a magnet (213).

7. The detection method of a device for detecting the wire feeding speed of a welding wire according to claim 1, characterized in that, Including the following steps: (1) Install driving wheels (104, 204, 304) on the output ends of the motors (102, 202, 302). After the welding wires (106, 206, 306) pass between the driving wheels (104, 204, 304) and the driven wheels (103, 203, 303), they are connected to the welding torches (101, 201, 301); (2) Install regular polygon nuts (105, 205, 305) at the central positions of the driving wheels (104, 204, 304); (3) Set a pulse signal timing system on at least one side of the regular polygon nuts (105, 205, 305). The pulse signal timing system is fixed relative to the motors (102, 202, 302). Ensure that during the process of the motors (102, 202, 302) driving the regular polygon nuts to rotate, at least one side of the regular polygon nuts (105, 205, 305) can trigger the pulse signal timing system to work. The pulse signal timing system measures the time interval t between the corresponding sides of the regular polygon nuts (105, 205, 305) rotating to the positions corresponding to the pulse signal timing system in turn; (4) The wire feeding length can be obtained according to the rotation radian and the circumference of the driving wheels (104, 204, 304), and then the wire feeding speed can be calculated according to the measured time interval.

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