DC argon arc welding process execution alarm method, device, electronic equipment and medium

Abstract

The invention discloses a DC argon arc welding process execution alarm method, device, electronic equipment and medium, the method comprises: S1: real-time sampling of welding parameters of a DC welding machine; S2: calculating the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment; S3: based on the change of the absolute value of the difference within a first set number of continuous sampling cycles, judging the current working stage of the DC welding machine, when judging that the DC welding machine is in the arc starting stage or the arc ending stage, returning to S2, when judging that the DC welding machine is in the stable working stage, executing S4; S4: calculating the sliding average value of the sampling value in the stable stage with a window width of the set sampling number; S5: judging whether the average value exceeds the first set threshold range of the stable stage, if so, giving an alarm prompt, otherwise, returning to S2. It is realized that the threshold range alarm judgment is performed on the executed process parameters only in the stable arc section of DC welding, avoiding illegal operations of welding personnel.

Description

Technical Field

[0001] The present invention belongs to the field of welding technology, and more specifically, relates to a direct current argon arc welding process execution alarm method, device, electronic equipment and medium. Background Art

[0002] In the field of welding manufacturing, the welding process is generally formulated by process personnel according to the design drawings. Taking DC argon arc welding as an example, the welding process will specify the DC argon arc welding process threshold range, such as the current range, welding voltage range, shielding gas flow range, etc. Under normal circumstances, when operating, the welder adjusts the welding machine output and gas flow output according to the process threshold range specified in the process to meet the process threshold requirements.

[0003] However, since increasing the welding current can increase the welding speed and enable welders to achieve better performance, in the absence of external monitoring, welders may artificially increase the welding current without authorization, causing the welding current to exceed the process threshold requirements and perform illegal operations, thereby posing quality risks to the welded products.

[0004] In order to solve this problem, welding process execution alarm devices have appeared. This type of device collects welding parameters and then simply compares the welding parameters with the set process threshold. When the welding process threshold is exceeded, an alarm is issued for the welding operation.

[0005] However, the existing solutions have the following problems:

[0006] 1) At the moment of arcing, the DC welding machine will use high frequency and high voltage to start the arc. At this time, the data acquisition will obtain a voltage of up to several thousand volts. At the same time, the welding current rises from zero to the set welding current. During this period, the welding voltage and welding current are both outside the specified welding process threshold range, which will cause the process threshold alarm to be false alarm;

[0007] 2) During the arc closing stage of the DC welding machine, the welding current will drop from the set value to zero. During this period, the welding current will exceed the welding process threshold range, which will cause the process threshold alarm to be false alarm;

[0008] 3) When the DC welding machine is in normal working condition, due to interferences such as grid voltage fluctuations, arc spatter, slag inclusions, pores, etc. encountered during the welding process, the welding current and welding voltage will fluctuate over a large range, resulting in exceeding the welding process range, and further causing the process threshold alarm to be falsely reported. Summary of the invention

[0009] The purpose of the present invention is to propose a DC argon arc welding process execution alarm method, device, electronic equipment and medium, which can accurately identify the disturbances of the arc starting, arc ending and normal stable arc segments of the DC welding machine, so as to perform threshold range alarm judgment on the executed process parameters only in the stable arc segment of DC welding, thereby avoiding illegal operations by welders.

[0010] In a first aspect, the present invention provides a DC argon arc welding process execution alarm method, comprising:

[0011] Step S1: real-time sampling of welding parameters of the DC welding machine;

[0012] Step S2: Calculate the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment;

[0013] Step S3: based on the change of the absolute value of the difference within a first set number of consecutive sampling periods, judging the current working stage of the DC welding machine; when judging that the DC welding machine is in the arc starting stage or the arc ending stage, returning to step S2; when judging that the DC welding machine is in the stable working stage, executing step S4;

[0014] Step S4: calculating the sliding average of the sampled values ​​in the stable phase with a window width of a set sampling number, and obtaining the average value of all the sampled values ​​within the window width of the set sampling number;

[0015] Step S5: Determine whether the average value exceeds the first set threshold range in the stable stage. If so, issue an alarm; otherwise, return to step S2.

[0016] Optionally, the welding machine parameter is a welding current or a welding voltage of a DC welding machine.

[0017] Optionally, in step S2, judging the current working stage of the DC welding machine based on the change of the absolute value of the difference within a first set number of consecutive sampling periods includes:

[0018] If the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is always greater than the second set threshold value within a first set number of consecutive sampling cycles, it is determined that the DC welding machine is currently in the arc starting stage or the arc ending stage;

[0019] If the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is always smaller than the second set threshold value within a first set number of consecutive sampling cycles, it is determined that the DC welding machine is currently in a stable working state.

[0020] Optionally, in step S4, the window width of the set sampling number is greater than 1 times the sampling frequency value.

[0021] In a second aspect, the present invention provides a DC argon arc welding process execution alarm device, comprising: a data acquisition module, a data calculation and judgment module, and an alarm display module;

[0022] The data acquisition module is used to sample the welding parameters of the DC welding machine in real time;

[0023] The data calculation and judgment module is used for:

[0024] Calculating the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment;

[0025] Based on the change of the absolute value of the difference within a first set number of consecutive sampling cycles, the current working stage of the DC welding machine is judged, and when it is judged that the DC welding machine is in the arc starting stage or the arc ending stage, the step of returning to the step of calculating the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment;

[0026] When it is determined that the DC welding machine is in a stable working stage, a sliding average calculation is performed on the sampling values ​​in the stable stage with a window width of a set sampling number to obtain an average value of all sampling values ​​within the window width of the set sampling number;

[0027] And, judging whether the average value exceeds a first set threshold range in the stable stage, if so, sending an alarm message to the alarm display module, otherwise, returning to the step of calculating the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment;

[0028] The alarm display module is used to display the alarm information.

[0029] Optionally, the welding machine parameter is a welding current or a welding voltage of a DC welding machine.

[0030] Optionally, the method by which the data calculation and judgment module judges the current working stage of the DC welding machine includes:

[0031] If the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is always greater than the second set threshold value within a first set number of consecutive sampling cycles, it is determined that the DC welding machine is currently in the arc starting stage or the arc ending stage;

[0032] If the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is always smaller than the second set threshold value within a first set number of consecutive sampling cycles, it is determined that the DC welding machine is currently in a stable working state.

[0033] Optionally, the window width of the set sampling number is greater than 1 times the sampling frequency value.

[0034] In a third aspect, the present invention provides an electronic device, the electronic device comprising:

[0035] at least one processor; and,

[0036] a memory communicatively connected to the at least one processor; wherein,

[0037] The memory stores instructions that can be executed by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can execute the DC argon arc welding process execution alarm method described in the first aspect.

[0038] In a fourth aspect, the present invention proposes a non-transitory computer-readable storage medium, which stores computer instructions, and the computer instructions are used to enable a computer to execute the DC argon arc welding process execution alarm method described in the first aspect.

[0039] The beneficial effects of the present invention are:

[0040] The method of the present invention simultaneously collects welding parameters in real time, calculates the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment, and based on the change of the absolute value of the difference within the continuous first set number of sampling cycles, it can accurately judge whether the DC welding machine is in the arc starting stage, the arc ending stage or the stable working stage, thereby effectively avoiding the false alarm caused by the welding parameter exceeding the threshold value in the arc starting stage and the arc ending stage. When it is judged that the DC welding machine is in the stable working stage, the sliding average value is calculated for the sampling value in the stable stage with the window width of the set sampling number, and the average value of all the sampling values ​​in the window width of the set sampling number is obtained. When the average value exceeds the first set threshold range of the stable stage, an alarm prompt is given. The present invention can effectively filter out the welding parameter disturbance caused by interference such as slag inclusion and pores through the sliding average value calculation, and avoid the false alarm caused by the welding parameter fluctuation caused by non-human factors such as network voltage fluctuation, arc splashing, slag inclusion, pores, etc., thereby realizing the threshold range alarm judgment of the executed process parameters only in the stable arc section of DC welding, and can effectively identify the artificial adjustment of welding parameters, identify the illegal operation of welding personnel and alarm, thereby ensuring the quality of welding process.

[0041] The system of the present invention has other characteristics and advantages, which will be apparent from the drawings incorporated herein and the following detailed description, or will be described in detail in the drawings incorporated herein and the following detailed description, which together serve to explain the specific principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The above and other objects, features and advantages of the present invention will become more apparent through a more detailed description of exemplary embodiments of the present invention in conjunction with the accompanying drawings, in which like reference numerals generally represent like components.

[0043] Figure 1 A typical DC TIG welding current graph is shown.

[0044] Figure 2 The welding current diagram of DC argon arc welding after being subjected to external disturbance is shown.

[0045] Figure 3 A step flow chart of a DC argon arc welding process execution alarm method according to Example 1 is shown.

[0046] Figure 4 A schematic diagram of a DC argon arc welding process execution alarm device according to an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0047] The present invention will be described in more detail below with reference to the accompanying drawings. Although preferred embodiments of the present invention are shown in the accompanying drawings, it should be understood that the present invention can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to make the present invention more thorough and complete, and to fully convey the scope of the present invention to those skilled in the art.

[0048] Example 1

[0049] like Figure 3 As shown, this embodiment provides a DC argon arc welding process execution alarm method, including:

[0050] Step S1: real-time sampling of welding parameters of the DC welding machine;

[0051] The welding machine parameter may be a welding current or a welding voltage of a DC welding machine. In this embodiment, the welding current is taken as an example for description.

[0052] Step S2: Calculate the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment;

[0053] Among them, judging the current working stage of the DC welding machine includes:

[0054] If the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is always greater than the second set threshold value within a first set number of consecutive sampling cycles, it is determined that the DC welding machine is currently in the arc starting stage or the arc ending stage;

[0055] If the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is always smaller than the second set threshold value within a first set number of consecutive sampling cycles, it is determined that the DC welding machine is currently in a stable working state.

[0056] In this embodiment, the first set number can be set according to actual needs, generally set to 3-5, and the second set threshold can be customized according to the current value change rate of the welding machine in the arc starting or arc ending stage.

[0057] Step S3: based on the change of the absolute value of the difference within the first set number of consecutive sampling cycles, the current working stage of the DC welding machine is judged. When the DC welding machine is judged to be in the arc starting stage or the arc ending stage, the process returns to step S2. When the DC welding machine is judged to be in the stable working stage, the process executes step S4.

[0058] Specifically, Figure 1 As shown in the figure, segment t0 is the arc starting segment, segment t1 is the arc ending segment, and Is is the current setting threshold of the welding machine in the stable stage (this value is a range value). It can be seen that the slopes of the arc starting and arc ending stages are significantly different compared with the stable arc segment. Sampling the welding current of the arc starting and arc ending segments can realize the judgment of the arc starting and arc ending segments:

[0059] 1) Arc starting stage judgment: S n -S n-1 >I th , where S n is the current sampling value, S n-1 is the sampling value at the previous moment. When the difference between the two is greater than a certain set threshold value I for several consecutive sampling cycles th When , it can be determined as the arc starting stage;

[0060] 2) Arc closing stage judgment: S n -S n-1 <-I th , where the definition of the operator is the same as that in the arc starting stage. When the difference between the two is less than a certain set threshold value for several consecutive sampling cycles, th When , it can be determined as the arc closing stage.

[0061] Comparing the two formulas, they can be unified as Abs(S n -S n-1 )>I th , that is, the absolute value of the difference between the previous and next sampling values. When several consecutive sampling cycles are greater than a certain threshold, it is determined to be the arc starting or arc ending stage.

[0062] Step S4: calculating the sliding average of the sampled values ​​in the stable phase with a window width of a set number of samples, and obtaining the average value of all sampled values ​​within the window width of the set number of samples;

[0063] Step S5: Determine whether the average value exceeds the first set threshold range in the stable stage. If so, issue an alarm; otherwise, return to step S2.

[0064] Specifically, this step is used to process the disturbance interference of the stable arc segment. Figure 2 As shown in the figure, it can be seen that when the stable arc segment is affected by external disturbances, the local segment presents a sawtooth shape. For example, when affected by grid voltage fluctuations, arc spatter, etc., the welding current or welding voltage will have a large instantaneous change; when the external disturbance disappears, the welding current or welding voltage will return to normal values.

[0065] Since the change of welding current or welding voltage caused by the disturbance can generally only last for less than 100ms, but the duration of the change of welding parameters caused by the disturbance is very difficult to identify in actual operation, the present invention samples the data of the stable arc segment, performs sliding average, and performs filtering processing to remove the parameter fluctuation caused by the disturbance in order to eliminate the false alarm caused by the disturbance. Specifically, the sampling points in the sliding window of fixed width are calculated segment by segment to obtain the mean of each sampling point in the sliding window width. The formula for calculating the sliding average is:

[0066]

[0067] Where n is the window width for sliding average calculation, and n corresponds to the number of sampling points for each sliding average calculation. n is related to the sampling frequency. Considering that the disturbance is generally less than 100ms, the number of sampling points corresponding to the n value in this embodiment should be greater than or equal to 1 times the sampling frequency value.

[0068] For example, the sampling frequency f=1kHz, that is, 1000 sampling points are collected in 1 second, and the sampling period is 1s. Since the duration of the disturbance is generally less than 100ms, in the specific implementation process, a sufficient number of sampling points are required to remove the welding current fluctuation interference caused by the disturbance. Therefore, the window width n value cannot be too small. The window width should cover the complete disturbance duration window, and there must be enough sampling points in the window to ensure accurate identification of the disturbance. Therefore, the window width n should be greater than the number of sampling points corresponding to 100ms. Therefore, the n value should preferably be greater than or equal to 1 times the sampling frequency, that is, n≥1000.

[0069] Taking n=1000 as an example, when 5 of the data points exceed the set current threshold range, after the sliding average processing, the average of the sampling points in the entire sampling cycle is still within the set threshold range. When the welding current is increased manually, the sampling points will actually exceed the set current threshold range. For example, of the 1000 points collected within the sliding window width, basically every point will exceed the threshold. Therefore, it is possible to accurately identify whether there is an illegal operation to increase the current during the welding process, and issue an alarm in time.

[0070] Example 2

[0071] like Figure 4 As shown, this embodiment proposes a DC argon arc welding process execution alarm device, including: a data acquisition module 1, a data calculation and judgment module 2 and an alarm display module 3;

[0072] The data acquisition module 1 is used to sample the welding parameters of the DC welding machine in real time;

[0073] The data calculation 2 judgment module is used for:

[0074] Calculate the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment;

[0075] Based on the change of the absolute value of the difference within a first set number of consecutive sampling periods, the current working stage of the DC welding machine is judged, and when it is judged that the DC welding machine is in the arc starting stage or the arc ending stage, the step of returning to the step of calculating the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is returned;

[0076] When it is determined that the DC welding machine is in a stable working stage, a sliding average is calculated for the sampling values ​​in the stable stage with a window width of a set sampling number to obtain the average value of all sampling values ​​within the window width of the set sampling number;

[0077] And, judging whether the average value exceeds the first set threshold range in the stable stage, if so, sending an alarm message to the alarm display module 3, otherwise, returning to the step of calculating the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment;

[0078] The alarm display module 3 is used to display alarm information.

[0079] In this embodiment, the welding machine parameter is the welding current or welding voltage of the DC welding machine.

[0080] In this embodiment, the method for the data calculation and judgment module to judge the current working stage of the DC welding machine includes:

[0081] If the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is always greater than the second set threshold value within a first set number of consecutive sampling cycles, it is determined that the DC welding machine is currently in the arc starting stage or the arc ending stage;

[0082] If the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is always smaller than the second set threshold value within a first set number of consecutive sampling cycles, it is determined that the DC welding machine is currently in a stable working state.

[0083] In this embodiment, the window width of the sampling quantity is set to be greater than 1 times the sampling frequency value.

[0084] Example 3

[0085] This embodiment provides an electronic device, the electronic device comprising:

[0086] at least one processor; and,

[0087] a memory communicatively connected to the at least one processor; wherein,

[0088] The memory stores instructions that can be executed by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can execute the DC argon arc welding process execution alarm method described in Example 1.

[0089] The electronic device according to an embodiment of the present disclosure includes a memory and a processor, and the memory is used to store non-temporary computer-readable instructions. Specifically, the memory may include one or more computer program products, and the computer program product may include various forms of computer-readable storage media, such as volatile memory and / or non-volatile memory. The volatile memory may, for example, include a random access memory (RAM) and / or a cache memory (cache), etc. The non-volatile memory may, for example, include a read-only memory (ROM), a hard disk, a flash memory, etc.

[0090] The processor may be a central processing unit (CPU) or other forms of processing units having data processing capabilities and / or instruction execution capabilities, and may control other components in the electronic device to perform desired functions. In one embodiment of the present disclosure, the processor is used to run the computer-readable instructions stored in the memory.

[0091] Those skilled in the art should be able to understand that in order to solve the technical problem of how to obtain a good user experience, the present embodiment may also include well-known structures such as a communication bus and an interface, and these well-known structures should also be included in the protection scope of the present disclosure.

[0092] For detailed description of this embodiment, reference may be made to the corresponding descriptions in the aforementioned embodiments, which will not be repeated here.

[0093] Example 4

[0094] This embodiment proposes a non-transitory computer-readable storage medium, which stores computer instructions. The computer instructions are used to enable a computer to execute the DC argon arc welding process execution alarm method described in Example 1.

[0095] According to the computer-readable storage medium of the embodiment of the present disclosure, non-transitory computer-readable instructions are stored thereon. When the non-transitory computer-readable instructions are executed by a processor, all or part of the steps of the above-mentioned methods of each embodiment of the present disclosure are executed.

[0096] The above-mentioned computer-readable storage media include, but are not limited to: optical storage media (e.g., CD-ROM and DVD), magneto-optical storage media (e.g., MO), magnetic storage media (e.g., magnetic tape or mobile hard disk), media with built-in rewritable non-volatile memory (e.g., memory card) and media with built-in ROM (e.g., ROM box).

[0097] The embodiments of the present invention have been described above, and the above description is exemplary, not exhaustive, and is not limited to the disclosed embodiments. Many modifications and changes will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments.

Claims

1. A DC argon arc welding process execution alarm method, characterized in that: include: Step S1: real-time sampling of welding parameters of the DC welding machine; Step S2: Calculate the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment; Step S3: based on the change of the absolute value of the difference within a first set number of consecutive sampling periods, judging the current working stage of the DC welding machine; when judging that the DC welding machine is in the arc starting stage or the arc ending stage, returning to step S2; when judging that the DC welding machine is in the stable working stage, executing step S4; Step S4: calculating the sliding average of the sampled values ​​in the stable phase with a window width of a set sampling number, and obtaining the average value of all the sampled values ​​within the window width of the set sampling number; Step S5: Determine whether the average value exceeds the first set threshold range in the stable stage. If so, issue an alarm; otherwise, return to step S2.

2. The DC argon arc welding process execution alarm method according to claim 1, characterized in that: The welding parameter is the welding current or welding voltage of the DC welding machine.

3. The DC argon arc welding process execution alarm method according to claim 1, characterized in that: In step S2, judging the current working stage of the DC welding machine based on the change of the absolute value of the difference within a first set number of consecutive sampling periods includes: If the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is always greater than the second set threshold value within a first set number of consecutive sampling cycles, it is determined that the DC welding machine is currently in the arc starting stage or the arc ending stage; If the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is always smaller than the second set threshold value within a first set number of consecutive sampling cycles, it is determined that the DC welding machine is currently in a stable working state.

4. The DC argon arc welding process execution alarm method according to claim 1, characterized in that: In step S4, the window width of the set sampling quantity is greater than 1 times the sampling frequency value.

5. A DC argon arc welding process execution alarm device, characterized in that: include: Data acquisition module, data calculation and judgment module and alarm display module; The data acquisition module is used to sample the welding parameters of the DC welding machine in real time; The data calculation and judgment module is used for: Calculating the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment; Based on the change of the absolute value of the difference within a first set number of consecutive sampling cycles, the current working stage of the DC welding machine is judged, and when it is judged that the DC welding machine is in the arc starting stage or the arc ending stage, the step of returning to the step of calculating the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment; When it is determined that the DC welding machine is in a stable working stage, a sliding average calculation is performed on the sampling values ​​in the stable stage with a window width of a set sampling number to obtain an average value of all sampling values ​​within the window width of the set sampling number; And, judging whether the average value exceeds a first set threshold range in the stable stage, if so, sending an alarm message to the alarm display module, otherwise, returning to the step of calculating the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment; The alarm display module is used to display the alarm information.

6. The DC argon arc welding process execution alarm device according to claim 5, characterized in that: The welding parameter is the welding current or welding voltage of the DC welding machine.

7. The DC argon arc welding process execution alarm device according to claim 5, characterized in that: The method for the data calculation and judgment module to judge the current working stage of the DC welding machine includes: If the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is always greater than the second set threshold value within a first set number of consecutive sampling cycles, it is determined that the DC welding machine is currently in the arc starting stage or the arc ending stage; If the absolute value of the difference between the sampling value of the welding parameter at the current moment and the sampling value at the previous adjacent moment is always smaller than the second set threshold value within a first set number of consecutive sampling cycles, it is determined that the DC welding machine is currently in a stable working state.

8. The DC argon arc welding process execution alarm device according to claim 5, characterized in that: The window width of the set sampling quantity is greater than or equal to 1 times the sampling frequency value.

9. An electronic device, characterized in that: The electronic device comprises: at least one processor; and, a memory communicatively connected to the at least one processor; wherein, The memory stores instructions that can be executed by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can execute the DC argon arc welding process execution alarm method described in any one of claims 1-4.

10. A non-transitory computer-readable storage medium, characterized in that: The non-transitory computer-readable storage medium stores computer instructions, which are used to enable a computer to execute the DC argon arc welding process execution alarm method described in any one of claims 1-4.

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